Sand screen selection by sand retention test: a review of factors affecting sand control design

Abstract

The installation of sand screens in open-hole completions in the wellbore is crucial for managing sand production. The main reason for using standalone screens in open-hole completions is their relatively reduced operational complexity compared to other sand control technologies. However, directly applying the screen to the bottom of the hole can lead to an incorrect screen type selection, resulting in an unreliable sand control method. To address this issue, a sand retention test is conducted to evaluate the performance of a standalone screen before field installation. Nevertheless, current sand retention test setups encounter several challenges. These include difficulties in identifying minimum retention requirements, interpreting results in the context of field conditions, and replicating field-specific parameters. The existing sand retention test introduces uncertainties, such as inaccurately replicating field requirements, inconsistent selection of wetting fluids, flow rates, and channel formation, leading to variations in the choice of the optimal screen using this test. In response to these challenges, this study aims to review the sand retention test and propose an improved sand retention method to overcome these problems. The focus of this article is to provide an in-depth analysis of previous sand retention test setups, their contributions to characterizing sand screens, and the parameters utilized in determining test outcomes. Additionally, this review outlines a procedure to investigate the impact of different particle sizes on screen erosion. Key findings emphasize the importance of using high-quality materials, proper screen design to resist damage and erosion, achieving acceptable natural packing behind the screen, and considering factors such as geology, wellbore conditions, and installation techniques. The analysis reveals that a high quantity of finer and poorly sorted sand increases sand production. The study recommends performing a sand pack test closer to reservoir conditions for better evaluation. Premium sand screens demonstrate the highest retention capacity, followed by metal mesh and wire-wrapped screens. Additionally, geotextiles show potential for enhancing sand retention, and screen design affects erosion resistance and service life.