Physical and Numerical Modeling of the Effect of Gravel Pack Size on Sand Production in Oil Wells by Designing and Manufacturing Machine

This research discusses the effect of gravel pack size on sand production by designing and manufacturing machine and a numerical model for simulating sand and gravel pack production. Different rocks and fluids can be tested under different stresses to simulate sand and gravel pack using this machine and the numerical model. In this study, sand with certain aggregation, gravel in different sizes, and water were used to simulate production of sand and gravel pack. PFC3D was used to create a numerical model. Sand size between 0.22-1.1 mm and gravel sizes between 3.54.76 mm, 4.769 mm, 9-12.6 mm, and 12.6-16.8 mm were used in the numerical model and gravel sizes between 4.76 – 9 mm and between 9.25 -19 mm were used in the physical model. The results obtained from the modeling showed that in the numerical model with the gravel pack sizes between 3.5-4.76 mm, production of sand was minimal; in the physical model with the gravel pack sizes between 4.76-9 mm, sand production was less and output flow rate of the fluid was more. In addition, the results of the physical model showed that after putting gravel pack, fluid production rate decreased over time and reached a constant amount. Therefore, it may be proposed that size of gravel pack between 4.76-9 mm is more suitable as far as fluid production rate and sand production prohibition is concerned.