Numerical simulations of sand‐screen performance in unconsolidated prepacked gravel screen

Abstract

This work addresses the ongoing challenge of optimizing sand control screens, attributed to a limited understanding of screen blocking. A novel one‐way computational fluid dynamics and discrete element method (CFD–DEM) coupling technique is presented to analyze the structural parameters of unconsolidated prepacked gravel screens (PPGS). CFD–DEM involves systematically investigating the width of the punched slot on the outer protective screen, the size of the gravel, and the efficiency of gravel packing to improve the antiblocking capability of unconsolidated PPGS. Results from numerical simulations reveal that under conditions of effective sand control, the amount of sand entering the gravel layer to the bridge (referred to as the sand pass rate) is positively correlated with the antilocking ability (referred to as oil productivity index) for unconsolidated PPGS. The efficiency of gravel packing has the most substantial effect on the antilocking performance of unconsolidated PPGS. The data suggest that appropriately reducing the efficiency of gravel packing can enhance the antilocking capability of unconsolidated PPGS. To design an unconsolidated PPGS with enhanced antilocking capability, the efficiency of gravel packing be determined first. Then, the gravel size is designed based on this efficiency, and the width relative to the gravel size is decided. This contemporary design principle diverges considerably from previous design principles for gravel‐packed sand control screens. Supporting validation experiments agree with simulation outcomes, suggesting the established one‐way CFD–DEM coupling method in this paper is suitable for analyzing the plugging mechanism of unconsolidated PPGS. Thus, the CFD–DEM coupling method improves the design of such screens for improved antiblocking performance.