Utilizing Computational Fluid Dynamics (CFD) Analysis as a Design Tool inFrac-Packing Applications To Improve Erosion Life (2006)

Utilizing Computational Fluid Dynamics (CFD) Analysis as a Design Tool in Frac Packing Applications to Improve Erosion Life Nicholas Jacob Clem; Nicholas Jacob Clem Baker Oil Tools Search for other works by this author on: This Site Google Scholar Martin P. Coronado; Martin P. Coronado Baker Oil Tools Search for other works by this author on: This Site Google Scholar Rustom Mody Rustom Mody Search for other works by this author on: This Site Google Scholar Paper presented at the SPE Annual Technical Conference and Exhibition, San Antonio, Texas, USA, September 2006. Paper Number: SPE-102209-MS https://doi.org/10.2118/102209-MS Published: September 24 2006 Cite View This Citation Add to Citation Manager Share Icon Share Twitter LinkedIn Get Permissions Search Site Citation Clem, Nicholas Jacob, Coronado, Martin P., and Rustom Mody. "Utilizing Computational Fluid Dynamics (CFD) Analysis as a Design Tool in Frac Packing Applications to Improve Erosion Life." Paper presented at the SPE Annual Technical Conference and Exhibition, San Antonio, Texas, USA, September 2006. doi: https://doi.org/10.2118/102209-MS Download citation file: Ris (Zotero) Reference Manager EasyBib Bookends Mendeley Papers EndNote RefWorks BibTex Search nav search search input Search input auto suggest search filter All ContentAll ProceedingsSociety of Petroleum Engineers (SPE)SPE Annual Technical Conference and Exhibition Search Advanced Search AbstractFrac packing tool erosion is becoming a growing concern as more high-profile deepwater wells are completed using this technique. Today many deepwater wells require frac pack pump rates of at least 40 barrels per minute (bbl/min) with proppant loads reaching 300,000 lbs. As zone lengths are increased and multi-zone operations are performed jobs requiring 60 bbl/min pump rates with proppant loads reaching 900,000 lbs. may be more typical. The current frac packing tool designs must be optimized to accommodate the higher pump rates and proppant volumes required to complete these deepwater wells.Computational fluid dynamics (CFD) analysis of these systems provides valuable insight to what is physically happening to the tools at these high pump rates and proppant loads. Analyzing various patterns, such as velocity, fluid path, erosion, and sand concentration at high rates helps identify critical areas within the system that require design optimization. CFD analysis is a cost effective alternative to trial-and-error testing, which can cost upwards of $150,000 per test and prolong the development phase.Two sizes of systems have been analyzed using CFD analysis and modified based on the results of that analysis. Full scale tests were also performed at 40 bbl/min on these two systems to compare the actual results with that of the CFD analysis. The CFD analysis was able to generate accurate profiles of the physical erosion patterns observed after the full scale tests were completed. Although CFD cannot accurately predict magnitudes for erosion rates, it can predict erosion profiles and velocity magnitudes. Research is currently ongoing to accurately predict erosion rate magnitudes.This paper will detail the development, analysis and qualification testing of a next-generation frac packing system capable of use in ultra-high-rate operations.IntroductionThere are currently two major areas of concern in any high-rate crossover tool system, which are used in all conventional frac packing applications. Those two areas are where the fluid, typically a slurry consisting of high-strength proppant in a gelled carrier fluid, rapidly changes direction to transition into a concentric annulus. The first area is a transition from the tubing into the mini-annulus via a ported sub called the Bypass Crossover Sub. Here, the flow exits the bypass sub and impinges upon the inner surface of the Packer Extension. The flow travels down the mini-annulus, formed in between the Service Tool and Packer Extension, until the flow reaches the second area of concern: where the fluid transitions into the annulus from the mini-annulus via a set of ports in the Packer Extension. The fluid exits through these extension ports and impinges upon the ID of the well bore casing. The fluid then travels down the annulus to the formation to induce fracture of the formation and subsequent annular pack. At a volumetric flow rate of 40 bbl/min flow velocities exceed 200 feet per second (ft/s) through the ID of the service tool. As the fluid transitions into the mini-annulus, it impinges upon the ID of the Packer Extension at approximately 45 degrees with velocities upwards of 200 ft/s. At this velocity and impingement angle the abrasive slurry being pumped erodes through the Packer Extension and dramatically alters the shape of the port in the Bypass Crossover Sub. The second area of concern experiences similar problems as the first. The flow exits the ports in the Packer Extension at approximately 140 ft/s and impinges upon the casing ID at a 90º angle. Erosion to these ports could prevent them from being sealed off for later downhole operations, and could compromise the integrity of the casing. To redesign these two areas, a better understanding of the flow dynamics through this area of the system was needed. Highly turbulent flow is difficult to analyze empirically; therefore, CFD analysis was used to validate the design changes. Keywords: Upstream Oil & Gas, computational fluid dynamic, application, Bypass Crossover Sub, sand control, CFD analysis, port, Packer Extension, society of petroleum engineers, hydraulic fracturing Subjects: Hydraulic Fracturing, Frac and pack, Sand Control, Completion Operations This content is only available via PDF. 2006. Society of Petroleum Engineers You can access this article if you purchase or spend a download.