Evaluation and Optimization of a Newly Developed Chemical for Sand Consolidation: HTHP Gas Wells

Sand production is a common problem in wells completed in unconsolidated or poorly consolidated formation. Several problems are associated with sand production including erosion damage, and plugging of the well and surface production equipment, such as lines, valves, etc. Various mechanical solutions have been implemented to control or eliminate sand production. Screenless completion is an alternative method to conventional sand control techniques. Screenless completion methodology involves sand consolidation, a field-proven technique which offers viable and effective strategies to prevent sand production throughout the life of the well. Sand production can lead to production loss through sand filling up, production tubing restrictions, etc. Consequently, the need for an effective sand control is mandatory. Sand consolidation is a promising technique due to significant advancement in chemicals development for sand control. The challenge with the chemical consolidation systems is their ability to provide the highest possible compressive strength with minimum permeability reduction. A newly developed sand consolidation system was assessed in this study for its effectiveness in both sand consolidation and retained permeability. Two techniques were investigated in preparation/conditioning of sand samples. Following the conditioning state, the sand samples were treated with equivalent amounts of the two components of the newly developed sand consolidation system (Resin-A and Resin-B). A consolidation chamber was used to cure sand under simulated downhole conditions of a temperature (300°F) and a stress of 3,000 psi. The consolidated sand sample prepared using 3 wt% KCl brine preflush was associated with a reduction in plug permeability of more than 99% with a compressive strength of 1,100 psi. In the second method, which employed a diesel preflush in the sand sample preparation step, an average permeability of 63 mD and unconfined compressive strength nearly 900 psi were obtained. The effect of temperature and flow rate on return permeability were investigate. The paper presents in detail the lab work conducted to evaluate/optimize a newly developed chemical system for sand consolidation in HT/HP gas wells.