U.S. patent number 3,670,817 [Application Number 05/087,296] was granted by the patent office on 1972-06-20 for method of gravel-packing a production well borehole.
This patent grant is currently assigned to Shell Oil Company. Invention is credited to Randolph J. Saucier.
United States Patent |
3,670,817 |
Saucier |
June 20, 1972 |
METHOD OF GRAVEL-PACKING A PRODUCTION WELL BOREHOLE
Abstract
A method of gravel-packing a well borehole extending into an
interval of a hydrocarbon-bearing subterranean earth formation by
determining the median size of the sand grains in the interval and
forming a pumpable slurry of liquid containing granular particles
having a relatively narrow range of grain sizes with a median grain
size from about 5 to 7 times larger than the median size of grains
in the interval. Perforations are formed in a conduit sized to
exclude passage of substantially all the slurried granular
particles and the conduit is positioned in the well borehole at a
depth adjacent to the interval, thereby forming an annulus between
the conduit and the interval. A fluid including the slurry is then
flowed into the annulus and into contact with the exterior of the
conduit until the annulus is substantially filled with the granular
particles. Fluids are then flowed from an injection well borehole
into the gravel-packed well borehole for recovering of
hydrocarbon-bearing fluids therefrom.
Inventors: |
Saucier; Randolph J. (Houston,
TX) |
Assignee: |
Shell Oil Company (New York,
NY)
|
Family
ID: |
22204322 |
Appl.
No.: |
05/087,296 |
Filed: |
November 5, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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820758 |
May 1, 1969 |
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Current U.S.
Class: |
166/252.1;
166/278; 166/268 |
Current CPC
Class: |
E21B
43/04 (20130101); E21B 43/16 (20130101) |
Current International
Class: |
E21B
43/04 (20060101); E21B 43/16 (20060101); E21B
43/02 (20060101); E21b 043/04 (); E21b
043/16 () |
Field of
Search: |
;166/250,252,266-275,276,278,227,51 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Novosad; Stephen J.
Parent Case Text
This application is a continuation of Ser. No. 820,758, filed May
1, 1969, now abandoned.
Claims
What is claimed is:
1. A method of gravel-packing a well borehole extending into an
interval of a hydrocarbon-bearing subterranean earth formation
comprising the steps of:
determining the median size of the sand grains in said
interval;
forming a pumpable slurry of liquid containing granular particles,
substantially all of said particles having a relatively narrow
range of grain size with a median grain size from about 5 to 7
times larger than the median size of grains in said interval;
forming perforations in a conduit sized to exclude passage of
substantially all of said slurried granular particles;
positioning said conduit in said well borehole at a depth adjacent
to said interval, thereby forming an annulus between said conduit
and said interval;
flowing a fluid including said pumpable slurry of liquid into said
annulus into contact with the exterior of said conduit; and
maintaining said fluid in contact with said conduit until said
annulus is substantially filled with said granular particles;
extending at least a second well borehole into communication with
said interval;
establishing fluid communication between said first-mentioned well
borehole and said second well borehole;
circulating fluid down said second-mentioned well borehole, through
said interval, through the perforations in said first-mentioned
well borehole, through said granular particles therein, and out the
conduit disposed in said first-mentioned well borehole; and
recovering hydrocarbons from said fluid flowing out of said
first-mentioned well borehole.
2. The method of claim 1 wherein the step of forming a slurry of
liquid containing granular particles includes the step of forming a
slurry of liquid containing rounded granular particles.
3. The method of claim 1 wherein the step of forming a slurry of
liquid containing granular particles having a median grain size
from about 5 to 7 times larger than the median size of grains in
said interval includes the step of selecting a median grain size of
approximately 6 times larger than the median size of grains in said
interval.
4. The method of claim 1 including the step of tightly packing said
granular particles in said annulus.
5. The method of claim 1 including the step of gradually increasing
the flow rate of said circulating fluid from said first-mentioned
well borehole to said second well borehole.
6. The method of claim 1 wherein the step of flowing a fluid
including said pumpable slurry of liquid includes the step of
flowing a low solids fluid including said pumpable slurry of
liquid.
7. In a process for gravel-packing a well in which a conduit having
openings sized to allow fluid to enter while excluding packing
granules is installed within a well and surrounded with packing
granules having sizes proportioned relative to the sizes of the
granules of an unconsolidated earth formation, the improvement
comprising:
proportioning the sizes of the packing granules relative to the
sizes of the earth formation granules so that the packing granules
have a relatively narrow range of sizes with a median size that is
from about 5 to 7 times larger than the median size of the earth
formation granules; and
installing said packing granules within the borehole of a well
around a conduit that has openings sized to exclude substantially
all of said packing granules.
8. The process of claim 7 in which the median size of said packing
granules is approximately 6 times larger than the median size of
the earth formation granules.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to gravel-packing a screen or liner in the
borehole of a well; and, more particularly, to a method for
preventing the movement around and into a well borehole of
individual particles comprising an unconsolidated rock
formation.
2. Description of the Prior Art
Many underground rock formations are unconsolidated or so poorly
consolidated that they disintegrate under the forces exerted upon
them by the weight of the overbearing rock and by the flow of
formation fluids into a well bore penetrating the formation. Such
rock formations are hereinafter referred to generally as
unconsolidated formations. It has been found that, when fluids flow
from an unconsolidated formation into a well borehole, the
displacement of formation particles into the well borehole permits
the movement of additional particles farther back in the formation
and results in plugging of the well borehole and of the formation
flow channels around the well borehole. To prevent the
rearrangement of the formation particles under the forces of fluid
flow and overburden pressure, it is necessary to prevent
substantially the movement of formation particles into the well
borehole. It is possible to assure the substantially complete
prevention of the movement of formation particles around or into
the well borehole by providing mechanical support for the formation
particles around the well borehole. Such mechanical support should
impart to the formation particles a force directed outwardly from
the well borehole whereby the formation particles are retained
essentially undisturbed during the production of formation
fluids.
Various methods have been suggested for alleviating the problems
involved in producing fluids from an unconsolidated formation. In
one such method, a slotted or otherwise perforated pipe or liner is
centralized in the well borehole and the annulus between the liner
and the wall of the well borehole is packed with gravel. The gravel
pack is used to filter the formation particles from the produced
fluids to prevent their entry into the liner.
Many advantages are visualized for the wellbore equipped with a
gravel-packed liner, all of which tend to increase its production
efficiency. When properly placed in the annular space between the
wall of the wellbore and the perforated liner, gravel supports the
walls, prevents caving of loose material against the liner and
serves to restrain sand from unconsolidated and disintegrating
strata so that it may not enter the wellbore. More effective
screening of sand, possible by this means, diminishes the
destructive influence of sand scouring on wellbore equipment and
tends to reduce maintenance costs. Equipment repairs and wellbore
clean-out operations are less frequent and the wellbore is able to
produce for a greater part of the time than would otherwise be the
case. The wellbore so protected is therefore capable of maintaining
a larger average monthly production rate. With gravel to sustain
the walls of the wellbore, it is possible to form and maintain a
hole of larger diameter through the producing formation without
elsewhere increasing the normal diameter of the wellbore or that of
the wellbore casing. The larger diameter hole through the producing
zone results in increased production efficiency.
To be effective in sand screening, it was heretofore believed to be
essential that the perforated liner be completely enveloped through
the producing formation with a gravel sheath of suitable thickness;
that the perforations in the liner be of such size as completely to
exclude all the gravel and that the gravel particles be of such
size and so compacted as to permit only the very smallest sand
particles to pass through with the formation fluids into the
wellbore. The coarser sand particles must bridge over the openings
between the gravel particles at or near the sand-gravel interface.
These coarse sand particles in turn serve as a barrier for finer
sand grains and thus, in time, a combination gravel-sand screen is
built up that is stable for the particular flow conditions
obtaining.
The size of the gravel particles should be proportioned to the
prevailing size of the sand particles to be restrained. Sand grains
are of assorted sizes and shapes and it is difficult to apply
mathematical principles to them. According to Coberly and Wagner in
"Some Considerations in the Selection and Installation of Gravel
Packs for Oil Wells," AIME Tech. Publ. No. 960, 1937, a gravel pack
having granular particles of 10 times the formation grain size at
the 10 percent coarse point on a cumulative sieve analysis would
provide effective sand control. Numerous failures using this
criterion were noted, especially under disturbed fluid flow
conditions. Tausch and Corley in "Sand Exclusions in Oil and Gas
Wells," 1958, Drilling and Prod. Prac., API, pp. 66-82, summarized
the gravel-packing situation and noted that conventional
gravel-packing processes comprise the steps of (a) conducting a
screen analysis of the size of the grains in the interval of earth
formation to be packed, (b) slurrying gravel particles having a
median size of about 8 to 14 times that of the 10 percent coarse
point of the screen analysis, and (c) installing the packing grains
and a screen having approximately sized perforations in the well in
the manner described above.
Thus, prior art procedures stress the importance of utilizing the
maximum feasible extent of a bridging effect in order to keep the
size of the packing grains as large as possible. Such sizes are
generally around 10 times the formation grain size. This teaching
is consistent with the known fact that the permeability of a mass
of particles tends to decrease with decreases in the size of the
particles. Known techniques have proven inadequate in coping with
sand production problems encountered in the field, especially under
disturbed flow conditions induced by surges and gas evolution.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved method for
gravel-packing a well borehole extending into a subterranean earth
formation.
It is a further object of this invention to provide a method for
gravel-packing a well borehole in such a manner that the
permeability of the pack remains unimpaired under disturbed flow
conditions.
These and other objects are preferably accomplished by determining
the median size of the sand grain in an interval of subterranean
earth formation and forming a pumpable slurry of liquid containing
granular particles having a relatively narrow range of grain sizes
with a median grain size from about 5 to 7 times larger than the
median size of grains in the interval. Perforations are formed in a
conduit sized to exclude passage of substantially all of the
slurried granular particles and the conduit is positioned in a well
borehole extending into the earth formation at a depth adjacent to
the interval, thereby forming an annulus between the conduit and
the interval. A fluid including the slurry is then flowed into the
annulus and into contact with the exterior of the conduit until the
annulus is substantially filled with the granular particles.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a vertical sectional view of a well borehole having a
gravel-packed slotted liner or screen placed therein in accordance
with the teaching of my invention;
FIG. 2 is a graph illustrating one of the features of my invention;
and
FIG. 3 is a vertical sectional view of the well borehole of FIG. 1
showing fluids being produced from the formation thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
During the normal operation of a gravel-packed well borehole
extending into a subterranean earth formation, I have found that
the effects of particle bridging should be minimized and the
effective permeability of specified relatively finely grained
gravel pack is actually greater than that of a conventional
relatively coarsely grained gravel pack. In accordance with my
invention, therefore, the use of a specified gravel size involves a
gravel packing process that is distinct in respect to using a
non-conventional item of data concerning the formation grain sizes
(i.e., the median size, rather than the 10 percent coarse size used
in prior art processes), a non-conventionally smaller packing grain
size and a non-conventionally smaller size of openings in the
screen or liner to be installed in a well borehole. Although the
techniques of my invention will be described further hereinbelow
with respect to perforated casing types of well completions,
obviously the same techniques are applicable to so-called "open
hole" types of well completions.
Referring now to the drawing, FIG. 1 shows a well borehole 10
extending through a subterranean earth formation 11 into
communication with a permeable interval 12. It is to be understood
that interval 12 is a relatively unconsolidated or poorly
consolidated portion of earth formation 11, thus raising problems
in producing hydrocarbons therefrom as discussed in detail
hereinabove.
Well borehole 10 is preferably cased, as at casing 13, with casing
13 cemented therein as is well known in the art. A wire-wrapped
screen or liner 14 is disposed in casing 13 adjacent to interval
12, thus forming an annulus 15 between casing 13 and screen 14.
Casing 13 is perforated at perforations 16, i.e., at a plurality of
points extending along screen 14.
In operation, gravel 17 is pumped into the annulus 15 from an
annulus outlet 18 into contact with the exterior of screen 14 until
the annulus 15, at least along substantially the entire extent of
interval 12, is packed with the gravel 17.
In accordance with my invention, the median size of the sand grains
in interval 12 is determined. A slurry of liquid is formed
containing granular particles having a relatively narrow range of
grain sizes and a median grain size from about 5 to 7 times larger
than that of the sands in interval 12. The screen 14 is selected so
that the perforations or openings 19 in the screen 14 are sized to
exclude passage of all the slurried granular particles.
Thus, the gravel 17 is slurried and pumped down annulus outlet 18
as discussed hereinabove. The liquid including the granular
particles (i.e., the gravel 17) flows out of perforations 16 into
interval 12 while depositing the gravel 17 in the annulus 15 and
the perforations 16.
The following information, obtained from laboratory testing, shows
the importance of median grain size ratio on gravel pack
effectiveness and that previously recommended criteria were shown
to be unsatisfactory.
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TABLE I
PARTICLES SIZE RATIO VERSUS PACK EFFECTIVENESS
Ratio of Ratio of Pack to Pack Median Formation to Formation Test
Median 10% Coarse Designation Grain Size Point Results of Test
__________________________________________________________________________
1411 14.7 10.7 Formation not retained 161 14.7 7.4 Formation not
retained 111 5.7 4.5 Formation retained 131 5.7 3.2 Formation
retained
__________________________________________________________________________
These tests confirm that, under severe conditions of operation, the
ratio of pack to formation median grain size must be less than
about 6 to minimize sand production.
Although the median pack-to-formation grain size ratio of about 5
to 7 results in using finer grain particles than those in prior art
gravel packs, such utilization does not result in a reduced
effective pack permeability because the reduction in pack
impairment by formation particles is more significant than
permeability reduction due to finer gravel packs. Rounded or frac
gravel is preferred to angular gravel to further reduce impairment,
as will be discussed further hereinbelow.
During operation of a gravel pack, formation sand may enter a
gravel pack and reduce the initial pack permeability k.sub.INIT to
an effective pack permeability k.sub.EFF. An empirical curve was
obtained of the ratio of k.sub.EFF /k.sub.INIT versus gravel to
sand grain size ratio.
To define the ratio of effective pack permeability to formation
permeability, the expression for permeability k may be taken from
Krumbein, W. and Monk, G., "Permeability as a Function of Size
Parameters of Unconsolidated Sand," Trans. AIME, Vol. 151, pp.
153-160, as:
where
C is a function of particle shape, packing and skewness;
d.sub.m = median grain size; and
.sigma. = standard deviation of the granular material.
If it is assumed that C for the pack and formation are the same,
then the desired ratio is: ##SPC1##
(as obtained empirically) and
k.sub.p = effective total permeability of the gravel;
k.sub.f = total permeability of the formation;
d.sub.mp = median pack grain size;
d.sub.mf = median formation grain size;
.sigma. .sub.f = standard deviation of the granular material of the
formation;
.sigma. .sub.p = standard deviation of the granular material of the
gravel pack;
q = volumetric flow rate; and
k.sub.INIT = initial unimpaired total permeability of the
gravel.
Assuming that .sigma. .sub.f = 0.7 or 0.2 and that .sigma. .sub.p =
0.2, equation (2) results in the two curves shown in the graph of
FIG. 2 after we have determined and plotted the values listed
hereinabove. FIG. 2 thus shows that in order to maintain the
highest pack-to-formation permeability ratio (that is, minimum well
impairment) as well as minimizing sand production, the median grain
size ratio (d.sub.mp /d.sub.mf) should be between 5 and 7.
EXAMPLE
For a range of typical formation sands, the following gravel packs
were required under the indicated conditions:
1. 0.060 - 0.040 inch (12-18 U.S. mesh). This pack was found to be
effective for formations having a median grain size between 0.168
and 0.25 mm.
2. 0.047 - 0.023 inch (16-30 U.S. mesh). This pack size was found
to be effective for formations having a median grain size between
0.114 and 0.164 mm.
3. 0.033 - 0.017 inch (20-40 U.S. mesh). This pack size was found
to be effective for formations having a median grain size between
0.088 and 0.124 mm.
Increasing the density and/or size of openings in the casing 13 may
effect the productivity of well borehole 10. It also makes the
impairment of any single perforation 16 less critical to overall
well production.
The foregoing discussions indicate that gravel pack sizing is
preferably based upon a median pack-to-formation grain size ratio
of 6 for operation under flow disturbances as would be induced by
surges and gas evolution. The utility of particle bridging in
gravel packs under disturbed flow is diminished so as to be
insufficient in designing a gravel pack. To minimize the influence
of formation grain size distribution the median grain size of the
formation is used rather than the 10 percent coarse grain size used
in prior art techniques. For an effective gravel pack, the maximum
gravel pack permeability occurs for a median pack-to-formation
grain size ratio between 5 and 7. Preferably, the gravel is packed
as tightly as possible in the openings 16 in the casing 13. In
flowing fluid down injection well borehole 21, out perforations
21a, through formation 12 for subsequent production of formation
fluids, as illustrated in FIG. 3 wherein like numerals refer to
like parts of FIG. 1, the initial flow rate is preferably increased
gradually rather than rapidly. Thus, pumping, heating, heat
exchanging and separating equipment may be used for circulating
fluids down injection well borehole 21 and into interval 12 and out
of at least a second producing well borehole 10, similar to well
borehole 10 of FIG. 1, as is well known in the art. Fluid
communication may be established between the boreholes by any means
known in the art, such as by hydraulic fracturing. Hydrocarbons are
then separated from the recovered formation fluids and the
circulating fluid is recovered and recirculated back into well
borehole 21. Rounded pack grains (i.e., frac sands) for the gravel
pack are preferred to angular particles to improve the possibility
of fine particles flowing through the pack, thus reducing pack
impairment tendencies. Low solids fluids are preferably used to
carry the gravel 17 during gravel pack placement to preclude
plugging of the pack during placement operations. Typical placement
fluids may be cleaned prepared saltwater or diesel.
Thus, in the method of my invention, the size of the packing grains
in the gravel pack is kept small enough to emphasize the absolute
stoppage of formation grains. The median size of the packing grains
is only from about 5 to 7 times larger than that of the formation
median grain size. The effective permeability of such a pack is
greater than that of both a conventionally designed pack in which
the grains are significantly larger and a pack in which the grains
are significantly smaller.
* * * * *