In Steam Assisted Gravity Drainage (SAGD) operations, condensed water dissolves the formation minerals and mixes with formation water, and its salinity changes over time. For the salinity levels below a critical salt concentration, brine reacts with the formation clays and affects their mobilization towards the production well. Migrated fine particles may plug the pore spaces around the well and reduce wellbore productivity. This paper aims to investigate the impact of water salinity on fines migration and permeability reduction. A large-scale pre-packed Sand Retention Tests (SRT) facility was employed to simulate SAGD well conditions. Brine with different NaCl salt concentrations was injected into synthetic sand-pack samples that are representative of the McMurray Formation. Flow rates were varied during the test, and fines migration along the sand-pack was traced. Differential pressures along the sand pack were recorded to calculate the permeability changes during the test. Samples of produced water were collected immediately below the coupon to measure the fines concentration. Testing parameters such as pH, clay mineralogy, temperature, and sand control specifications were kept constant in all tests. Fines concentration in the produced water during the test and retained permeability were considered as the indicators of the fines migration inside the sand-pack. Results of step-rate testing display a jump in fines concentration in produced water right after each flow rate increase. Besides, fines concentration results show that fines migration was insignificant when using brine with high salt concentrations. Fines migration was stronger for a relatively narrow salinity range with low NaCl concentrations, resulting in the highest pore plugging. The findings in this research are consistent with past studies which relate clay dispersion to the zeta potential of clay materials: the higher the zeta potential, the stronger the fines dispersion and migration. Based on this study, it is recommended that the operating companies monitor the chemical properties of the produced water. Field operators could preserve the reservoir productivity by manipulating the formation salinities to lower the dispersion and detachment of fines and their migration towards the production well.

Summary Wire-wrapped screens (WWSs) are one of the most-commonly used devices by steam-assisted gravity drainage (SAGD) operators because of the capacity to control plugging and improve flow performance. WWSs offer high open-to-flow area (OFA) (6 to 18%) that allow a high release of fines, hence, less pore plugging and accumulation at the near-screen zone. Over the years, several criteria have been proposed for the selection of aperture sizes on the basis of different industrial contexts and laboratory experiments. Generally, existing aperture-sizing recommendations include only a single point of the particle-size distribution (PSD). Operators and academics rely on sand-control testing to evaluate the performance of sand-control devices (SCDs). Scaled laboratory testing provides a straightforward tool to understand the role of flow rate, flowing phases, fluid properties, stresses, and screen specifications on sand retention and flow impairment. This study employs large-scale prepacked sand-retention tests (SRTs) to experimentally assess the performance of WWSs under variable single-phase and multiphase conditions. The experimental results and parametric trends are used to formulate a set of empirical equations that describe the response of the WWS. Several PSD classes with various fines content and particle size are tested to evaluate a broad range of PSDs. Operational procedures include the coinjection of gas, brine, and oil to emulate aggressive conditions during steam-breakthrough events. The experimental investigation leads to the formulation of predictive correlations. Additional PSDs were prepared to verify the adequacy of the proposed equations. The results show that sanding modes are both flow-rate and flowing-phase dependent. Moreover, the severity or intensity of producing sand is greatly influenced by the ratio of grain size to aperture size and the ability to form stable bridges. During gas and multiphase flow, a dramatic amount of sanding was observed for wider apertures caused by high multiphase flow velocities. However, liquid stages displayed less-intense transient behaviors. Remarkably, WWSs rendered an excellent flow performance even for low-quality sands and narrow apertures. Although further and more complete testing is required, empirical correlations showed good agreement with experimental results.

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Slotted liners are widely used in steam-assisted gravity drainage (SAGD) wells to control sand production and sustain wellbore productivity. The slotted liner can provide desirable performance when appropriately designed. A literature review indicates a limited number of studies that offer design criteria specifically for SAGD wells. Moreover, past criteria seem to neglect some key factors, which may lead to inadequate slot design. This paper proposes a set of graphical design criteria for slotted liners in SAGD production wells, using prepacked sand retention testing (SRT) data. The SRT is designed to incorporate several essential factors that are not present in the past design criteria, such as slot density, steam breakthrough, and particle size distribution (PSD). The proposed design criteria are presented graphically for normal and aggressive conditions, where the aggressive condition accounts for the potential occurrence of the steam breakthrough. It is found that the upper bound of the design window is substantially lower for the aggressive condition due to the higher sand production after the steam breakthrough. The design criteria also indicate that the slotted liner is suitable only for the formations with low fines content.

This study presents an evaluation of Wire-Wrapped Screens (WWS) performance for SAGD production wells based on Pre-packed Sand Retention Testing (SRT). The impacts of features such as flow rates, water cut, steam-breakthrough events and fluid properties on flow performance and sand production are analyzed. The aim is to obtain a better understanding of WWS performance under several SAGD operational conditions for typical sand classes in the McMurray Formation in Western Canada. The study employs a large pre-packed SRT to assess the performance of WWS with different aperture sizes and standard wire geometries. The testing plan includes sand samples with two representative particle size distributions (PSD's) and fines contents. Testing procedures were designed to capture typical field flow rates, water cut, and steam-breakthrough scenarios. The amount of sand production and pressure drop across the zone of the screen and adjacent sand were measured and used to assess the screen performance. Furthermore, fines production was measured to evaluate plugging tendencies and flow impairment during production. The experimental results and data analysis show that aperture selection of WWS is dominated by their sand retention ability rather than the flow performance. The relatively high open flow area (OFA) makes WWS less prone to plugging. There is an increase in flow impairment after finalizing the injection scheme (oil+water+gas); however, it is controlled over the acceptable margins even with a narrow aperture. Further, a comparison of initial and final turbidity measurements showed that fines mobilization and production during single-phase brine flow was higher than in two-phase brine-oil flow at the same liquid flow rate. Excessive produced sand was observed for wider slots during the multi-phase (brine, oil, and gas) flow when gas was present, highlighting the impact of the breakthrough of wet steam on sand control performance. Flow impairment and pressure drop evolution were strongly related to the mobilization and accumulation of fines particles in the area close to the screen coupon; it is critical to allow the discharge of fines to maintain a high-retained permeability. Results also signify the importance of adopting adequate flow rates and production scenarios in the testing since variable water cuts and GORs showed to impact both sanding and flow performances. This research incorporates both single-phase and multiphase flow testing to improve design criteria for wire-wrapped screens and provide an insight into their performance in thermal recovery projects. An improved post-mortem analysis includes fines production measurements to correlate these to the retained permeability caused by the pore plugging, which has hardly been evaluated in previous studies.

Wire-wrapped screens have been established as one of the primary sand control devices in Steam-Assisted Gravity Drainage (SAGD) wells due to the high open-to-flow area and superior plugging attributes. However, their design is still a point of interest for thermal operations. Generally, existing approaches rely on one or more particular points of reservoir sands’ particle size distribution (PSD) and rules of thumb inferred from other devices like the slotted liners. This study used Sand Retention Testing (SRT) to analyze the performance of WWS under various testing conditions, which were neglected in the current design criteria. The experimental investigation leads to a set of graphical design criteria that provide an optimum aperture size window. The results show that the sand retention performance of WWS is highly dependent on the flow velocities of the wetting phase. Moreover, the testing showed satisfactory plugging performance of WWS even with narrow aperture sizes, proving a superior performance for low-quality oil sands.

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