Micronized Weighting Agents for Sand Screen Well Completion
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Solution Overview
Problem
High-density completion fluids used in well completions are expensive, hazardous, and can damage producing zones, while solids-laden drilling fluids can plug sand screens and impair production rates.
Innovation Solution
A wellbore fluid comprising a base fluid and micronized weighting agents with particle sizes ranging from 1 to 25 microns, which may be coated with dispersants, is used for drilling and completing wells, allowing the fluid to remain in the wellbore during completion operations without plugging sand screens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high-density completion fluids are used to control formation pressure, then formation pressure control is improved, but cost and hazard increase
Solution Approach 1:
The patent changes the particle size parameter of weighting agents from conventional larger sizes to micronized sizes (1-25 microns), allowing the fluid to maintain high density for pressure control while the fine particles can pass through sand screens without plugging, thereby reducing the harmful effects of screen plugging and associated costs
Solution Approach 2:
The patent uses micronized weighting agents that can be easily pumped and disposed of after completion, replacing expensive and hazardous high-density brines. The micronized particles are less problematic for environmental and disposal concerns, reducing both cost and hazard
2Stress or pressure
If conventional drilling fluids with solids are used, then hydrostatic pressure is maintained, but sand screens get plugged and production rates decrease
Solution Approach 1:
The patent changes the particle size distribution of solids in the drilling fluid to micronized weighting agents (1-25 microns), which are fine enough to pass through sand screens during completion operations while still providing the necessary hydrostatic pressure, thus maintaining both pressure control and production rates
3Productivity
If micronized weighting agents are used, then screen plugging is reduced, but fluid density control becomes more challenging
Solution Approach 1:
The patent optimizes the particle size parameters of micronized weighting agents (d90 of 1-25 microns, d50 of 0.5-10 microns) to balance two requirements: fine enough to pass through sand screens without plugging, yet sufficient to provide the needed hydrostatic pressure. This precise parameter control resolves the contradiction between screen flow capability and fluid density control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of micronized weighting agents with dispersant coatings reduces the risk of plugging sand screens and maintains hydrostatic pressure control, decreasing rig time and eliminating the need for costly high-density brines, while ensuring safe and effective well completion.
Implementation Method 1
The completion fluid is selected to have a density sufficient to create an overbalanced hydrostatic pressure regime at the location(s) of the wellbore perforations, thereby preventing formation fluids from entering the wellbore
Implementation Method 2
The micronized weighting agent may be coated with a dispersant
Data Source
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AI summary
A method for drilling and completing a wellbore that includes drilling a wellbore through a subterranean formation with a wellbore fluid, the wellbore fluid comprising: a base fluid; and micronized weighting agent; and disposing a sand screen in an interval of the wellbore with the wellbore fluid is disclosed.