A Comprehensive Review of Screen Plugging during Openhole Sand Control Completions Installation: Causes, Consequences, and Best Practices

In openhole completions, screens are one of the very common equipment used to control production of solids. Screens could get plugged during installation in case of improper wellbore fluid conditioning and displacement. Awareness of screen plugging is not widely spread, and many practicing engineers do not pay enough attention to its implications. In this paper, we discuss the causes, consequences, and ways of determining plugging and recommend best practices to reduce the risk of screen plugging. First, we review the various reasons for screens to get plugged during openhole completion installations and explain in detail undesirable events caused by screen plugging such as: Inability to properly displace wellbore fluids Inability to fully pack the screen annulus Damage to screens during displacement and gravel packing We also review downhole gauge data of several jobs to identify and discuss screen plugging signatures and their outcomes. Additionally, we discuss potential preventive measures. In openhole completions, it is very common to run screens in wellbores containing solids-laden fluids intentionally or unintentionally. Poor wellbore displacement or improper fluid conditioning can result in leaving some bigger size solids in the screen-running fluid (SRF), which could plug the screens. Also, the exposure of reactive shales to water-based fluids can destabilize the shales and lead to plugging. In some cases, the SRF quality control is not properly accounting for the actual flow inside the screen while running in hole, resulting in a false pass. We present several case histories of downhole gauge data analysis, showing evidence of screen plugging leading to excessive treating pressure, incomplete gravel pack, and, in a few cases, screen erosion during gravel pack operations. To prevent screen plugging, it is necessary to properly model all the displacement stages, pay attention to proper conditioning and quality control of the fluid, and ensure compatibility of the fluids with shales. A comprehensive review of screen plugging during sand control installation phase and its potential consequences supported with extensive downhole gauge data has not been published previously. This paper will be a valuable source of knowledge for completion engineers and help them better design and execute future operations.