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Abstract
The Boscan Field, Maracaibo, Venezuela is using a unique
approach to sand control. The completions use a combination
of premium sand control screens and artificial lift that are de-
signed to have a controlled level of sand production.

The Boscan formation is considered unconsolidated due
to the lack of cementing agents, and the nature of the mineral-
ogy. Lab studies have shown that low drawdowns will initiate
sand production, and field experience shows that the draw-
down caused by the artificial lift techniques used does induce
sand production. Several other factors such as the crude
which has a 10 API gravity and a viscosity that ranges from
300 to 2000 cps also affect the completions in the Boscan
Field. In addition, the productive intervals range from 300 to
600 ft in length with large shale breaks between zones in
many cases.

There have been several types of sand control imple-
mented in the Boscan Field. The major methods of sand con-
trol prior to 1996 were stand-alone and gravel packed slotted
liners. Since 1996 the completions have included open hole
and cased hole completions using a variety of sand retention
methods that include 12 & 16 gauge all weld and pre-packed
screen, stand alone low profile screens, and premium all
metal screens.

This paper discusses a lab study that evaluated several
types of sand control screens for stand-alone and gravel
packed completions using a technique developed by Chevron-
Texaco Exploration & Production Technology Company
(EPTC) (8). The mineralogical characteristics of the forma-
tion that contribute to the sanding potential of the field are
described. The rational for using a sand control technique that
allows a certain amount of sand production is discussed in
detail. In addition, production data including sand production
for several types of completions are compared.

Introduction
A field and laboratory study was undertaken to evaluate the
relative effectivness of two sand control approaches for a field
in Venezuela an effort to optimize the operating costs. One
part of the study was a laboratory evaluation to determine the
relative sand control efficiency of several screens for stand
alone, and gravel packed completions. The second part of the
program was a field evaluation of the relative effectiveness of
gravel packed and stand alone completions.

Even though there are several papers that discuss sand
control screens (1-7), none of the articles discuss analytical
methods of evaluating the screens. The lab program used a
method of evaluating the relative performance of sand control
screens developed at ChevronTexaco Exploration & Produc-
tion Technology Company (EPTC) known as the Screen Effi-
ciency (SE) Test to evaluate several screen types (8). The test
program included a new screen with an innovative approach to
sand control recently introduced in the area by a major service
company. The innovative screen, designated as "Screen M"
for purposes of this article has shown very acceptable per-
formance in several wells in the field.

The results of the laboratory evaluation showed that the
combination of gravel packing with all the screens evaluated
provides equivalent sand control. The evaluation of the stand
alone screens showed various levels of sand control. The 12
gauge screen provided only minimal sand control; whereas,
the slotted liner plugged very quickly. The test results did
show that Screen M took longer to "plug" than any of the
stand alone screens tested, and allowed a relatively consistent
level of sand to pass through as a function of
pressure differential.

Based on the simplicity of the completion, production,
and laboratory results, Screen M was recommended for stand
alone sand control completions in the Venezuelan field. How-
ever, it was noted that gravel packed completions with any of
the screens tested provides the best sand control.

SPE 74394
Producing Sand for Sand Control: A Novel Approach
David R. Underdown, SPE, ChevronTexaco Exploration & Production Technology Company
John Sanclemente, SPE, ChevronTexaco Tengiz
2 DAVE UNDERDOWN AND JOHN SANCLEMENTE SPE 74394
Well Completions
Sand production in the Venezuelan field is a result of several
factors. The formation is unconsolidated due to the lack of
cementing agents, and the nature of the minerology. In addi-
tion the large amount of water produced carries solids into the
wellbore. The method of production can also cause sanding
problems. Studies have shown that draw downs from 100 -
400 psi can initiate sanding from the formation. The use of
electrical submersible pumps are causing sanding by inducing
draw downs in the order of 1000 psi.

There have been several types of sand control impli-
mented in this particular Venezuelan field. The major method
of sand control prior to 1996 were stand alone and gravel
packed slotted liners. Since 1996 the completions have in-
cluded open hole and cased completions using a variety of
sand retention methods that include 12 and 16 gauge all weld
and pre-packed screens, stand alone low profile screens, and
premium screens.

Venezuelan Requirements
The objective of this study was to compare the relative sand
control performance of several screen types in simulated
stand-alone and gravel packed completions. The screens used
in the evaluation are listed in Table I.

Figure 1 shows a cut away of the screen from Company A
designated as Screen M. As shown, the screen consists of a
layer of stainless steel metal mesh on a base pipe, protected by
an outer shroud. Figure 2 is a close up of the stainless metal
mesh used to control the sand. The mean opening in the com-
pressed mesh is advertised as about 225 microns with a distri-
bution from 15 - 650 microns. The average inflow area
is 8 - 18%.

Each of the screens listed in Table I were evaluated as
stand-alone screens and in combination with a gravel pack
sand. Gravel pack completions were simulated using 16/30
U.S. Mesh sand. Several sieve analyses from several wells in
the Venezuelan field were reviewed to obtain a "typical" parti-
cle size distribution for the test program. The sieve analysis of
the sand used as the model for all the tests discussed in this
paper is given in Table II.

Screen Efficiency Results
The Screen Efficiency Test (8) consists of pumping a fluid
containing a known amount of simulated formation solids
through a sample of sand control screen at a constant rate.
The solids have a particle size distribution similar to the for-
mation of interest. The pressure build-up; i.e., the Pressure
Profile, and amount of solids that pass through the screen
sample as a function of time; i.e., the Gravimetric Profile, are
recorded. In order to better understand the relationship be-
tween the Pressure Profiles and the Gravimetric Profiles, a
methodology was developed called a SE Plot (Screen Effi-
ciency Plot). The SE Plot shows the normalized relationship
between the Performance Factor and the Sand Control Factor.
The Performance Factor and the Sand Control Factor are re-
lated to the pressure profile and gravimetric analysis
as follows:

Performance Factor = T/Ap
and
Sand Control Factor = 1/ Ag

The higher the Sand Control Factor the better the screen is
at controlling solids going through the screen. The higher the
Performance Factor, the longer the screen takes to plug.
Therefore, a screen with a high Sand Control and Performance
Factor the better the screen is at controlling sand and the
longer it takes to plug.

The Screen Efficiency Plot shown in Figure 3 is a result
of the data generated from the "plugging" ; i.e., Screen Effi-
ciency tests done using simulated formation sand. Inspection
of the SE Plot shows that screens in combination with gravel
pack sand provide the best sand control and above average
performance. The data depicted in Figure 3 also shows that
based on classical sand control screen requirement to control
sand, Screen M is not very efficient. This is evidenced by the
low Sand Control and Performance Factor. The perfect screen
would not plug for a long time and would not let much sand
through. Screen M lets a great deal of sand through as the
pressure builds. This trend is reflected in the generation of the
Performance Factor.

Using the classic criteria for sand control screens, the SE
Plot suggests gravel packing any of the screens tested provides
the best sand control for the Venezuelan field. However, it is
important to combine the needs of the field operation with the
performance characteristics of the screen. In the case of the
Venezuelan field, a screen that controls sand "too good" may
not have the life required for good economics. In addition, the
nature of the field operation in the Venezuelan field where
artificial lift is used, allows use of a sand control screen that
allows some influx of fine sand. Based on the criteria for sand
control screens in the Venezuelan field, and the nature of the
production of the crude using artificial lift techniques, the use
of the Screen M in stand-alone completion was recommended.

An interesting field observation in the wells that incorpo-
rate Screen M in a stand-alone application is that the comple-
tions exhibit "bursts" of sand production as the draw down is
increased during the life of the well. The results of the SE
Tests helps to understand the reason for the event. Figure 4
shows the raw data for the Pressure Profile of another type of
woven metal mesh material found in a commonly used pre-
mium sand control screen. This woven metal mesh has a D
50

very similar to that of the filtration media of Screen M. The
pressure profile of woven metal mesh is as expected. The
Pressure Profile increases gradually as the screen starts to
plug. It is important to note that the Pressure Profile is rela-
tively "smooth" with only a few minor downward fluctuations
up to the 100 psi cut off point.
SPE 74394 PRODUCING SAND FOR SAND CONTROL: A NOVEL APPROACH 3
Figure 5 is a Pressure Profiles of the Screen M media. It
is important to note the "wild" fluctuations in the Pressure
Profile up to the 100-psi cut off point. In addition, the gra-
vimetric profile for the Screen M media given in Figure 6
which is a combination of the Pressure Profile data and Gra-
vimetric Profile for Screen M shows a very large amount of
solids passing through the screen. The fact that the media of
Screen M passes a large amount of solids is not surprising.
Visual inspection of the filtration media of Screen M in Figure
2 shows a wide variation in the pore throat distribution. The
downward fluctuations are thought to represent sudden
"bursts" of solids through the screen as the screen media de-
forms with the increased pressure differential, or from sand
arches suddenly collapsing inside the screen media. These
observations are very similar to that observed with Screen M
in stand-alone completions in the field.

Field Evaluation
Several wells have been completed using Screen M with out
gravel packing. The technique has proven relatively straight
forward, and is much more cost effective than gravel packing
around wire wrapped screens. Both types of completions pro-
duce a measurable amount of very fine sand; however, the
facilities are set up to handle the solids. An evaluation of the
wells completed using Screen M and wells completed using
gravel packs around wire wrapped screens is shown in Figure
7. Inspection of Figure 7 shows that both completion tech-
niques provide about the same production for the time of the
evaluation. As a result of this evaluation and the cost effec-
tiveness of the completion, use of Screen M without gravel
packing is the preferred method of completion.

Conclusions
The following conclusions and observations are based on the
data presented in this paper:

1. The media of Screen M takes longer to "plug", and con-
sistently allows a greater quantity of sand to pass through
the media compared to all the screens tested for a stand-
alone completion

2. The media of Screen M allows sand to pass through in
"spurts" as the pressure differential is increased across
the media

3. A 12 gauge slotted liner "plugs" extremely fast in a stand-
alone completion as compared to all the screens tested

4. Gravel packing with 16/30 U. S. Mesh gravel pack sand
provides equivalent sand control with all the
screens tested

Nominclature
T = time for the pressure profile to reach 100 psi
Ap = total area under the curve of the pressure profile
Ag = total area under the gravimetric profile

Acknowledgements
The authors of this paper would like to thank EPTC, the Chev-
ronTexaco Business Unit, and PDVSA for permission to pub-
lish this paper.

References
1. Ali, S. A.," Sand Control Screens Exhibits Degrees of Plug-
ging," Hart's Petroleum Engineering International, July, 1996.

2. Lau, H. C. and Davis, C. L. ,"Laboratory Studies of Plugging
and Clean-Up of Production Screens in Horizontal Wellbores,"
SPE 38638, Presented at 1997 SPE Annual Technical Confer-
ence, San Antonio, Texas, October 5-8 1997.

3. Marken, C., and Rrvik, O., "Criteria for Production of Drilling
Fluids through Sand Control Screens", SPE 38187, presented at
European Formation Damage Conference, The Hague, The
Netherlands, June 2-3 1997.

4. Schulien. S., Ovsthus, J., Hestenes, L., Neigart, B., and Nistad,
T., "Scale Formation and Treatment in and Around Sand Control
Screens", SPE 37305, presented at SPE International Sympo-
sium on Oilfield Chemistry, Houston, Texas, February 18-21,
1997.

5. Browne, S., Ryan, D., Chambers, B., Gilchrist, J., and Bamforth,
S., "Simple Approach to the Cleanup of Horizontal Wells with
Prepacked Screen Completions", SPE 30116, presented at the
SPE European Formation Damage Conference, The Hague, The
Netherlands, May 15-16 1995.

6. Lester, G., Malgrel, C., and Whitlock, M., " Field Application of
a New Cleanable and Damage Tolerant Downhole Screen", SPE
30132, presented at the SPE European Formation Damage Con-
ference, The Hague, The Netherlands, May 15-16 1995.

7. Markestad, P., "Selection of Screen Slot Width to Prevent Plug-
ging and Sand Production", SPE 31097, presented at the SPE
Formation Damage Symposium, Lafayette, La, Feb. 14-16,
1996.

8. Underdown, D.R., Dickerson, R.C., Vaughan, W. T., "The
Nominal Sand Control Screen: A Critical Evaluation of Screen
Performance", SPE 56591, presented at the National SPE Con-
vention, Houston, Texas, Oct. 3 - 6, 1999.

SI Metric Conversion Factors

in. X 2.54 * E + 00 = cm
psi X 6.894 757 E + 00 = kPa
bbl X 1.589 873 E - 01 = M
3
ft X 3.04P* E 01 = m

* Conversion factor is exact


4 DAVE UNDERDOWN AND JOHN SANCLEMENTE SPE 74394


TABLE I
SAND CONTROL SCREENS

COMPANY SCREEN
A Stainless steel metal mesh
B Heavy duty wire wrapped 0.090" x 0.140" house shaped
wire
C 12 Gauge wire wrapped
D 12 Gauge slotted liner



TABLE II
SIEVE ANALYSIS OF SAND USED IN
SCREEN EFFICIENCY TESTS


US MESH MICRONS WT %
30 600 0
35 500 0
45 355 0
69 250 8.7
80 180 34.2
120 125 32.0
170 90 7.7
230 63 5.7
270 53 1.7
325 45 ---
>325 1 10.0
100



















SPE 74394 PRODUCING SAND FOR SAND CONTROL: A NOVEL APPROACH 5
FIGURE 1
CUT AWAY OF SCREEN "M"



















FIGURE 2
STAINLESS STEEL MESH
SCREEN "M"

































6 DAVE UNDERDOWN AND JOHN SANCLEMENTE SPE 74394
FIGURE 3
SCREEN EFFICIENCY PLOT
VENEZUELAN FORMATION SAND
























FIGURE 4
PRESSURE PROFILE OF
PREMIUM WOVEN METAL MESH



























0. 000
0. 200
0. 400
0. 600
0. 800
1. 000
1. 200
0. 000 0. 200 0. 400 0. 600 0. 800 1. 000 1. 200
PEF ORMANCE F ACT OR
Sc r een M S t and Al one 12 Ga u g e St and Al one Sc r een M w i t h 16/ 30
12 Ga u g e Wi th 16/ 30 Hous e Shaped W i r e wi th 16/ 30 S lot t ed Li ner W i th 16/ 30

SPE 74394 PRODUCING SAND FOR SAND CONTROL: A NOVEL APPROACH 7
FIGURE 5
PRESSURE PROFILE
SCREEN M MEDIA





















8 DAVE UNDERDOWN AND JOHN SANCLEMENTE SPE 74394
FIGURE 6
PRESSURE AND GRAVIMETRIC PROFILES
SCREEN "M" MEDIA



























FIGURE 7
COMPARISON OF PRODUCTION DATA






















0
10
20
30
40
50
60
70
80
90
100
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
VOLUME/SQ. IN ( LITERS)
0
10
20
30
40
50
60
70
80
90
100

180 Day Production Data
New Wells Completed January - November 1999
3.24 3.53
22
17
0.00
5.00
10.00
15.00
20.00
25.00
Gravel Packed Wells Non-Gravel Packed
Using Screen M
BOPD/ft
No. Wells