Optimizing Tubing Size for Effective Sand Transportation and Extended Life of ESP-Assisted Wells

Abstract The study examines the minimum sand transport velocities needed for different tube sizes to prevent ESP (Electric Submersible Pump) tripping and extend the lifespan of inclined wells. The methodology involves observing sand bed conditions at varying superficial liquid velocities (VSL) across different tube sizes, utilizing both OLGA modeling and experimental analysis. The studies were carried out using pure water, and the OLGA models were created based on completion schematics and fluid composition data. Sand transport phenomena were simulated with OLGA's sophisticated particle flow module, while Multiflash was used for thermodynamic fluid modeling. According to our findings, the minimum sand transport velocity is consistent across different tube diameters, specifically 2″, 2.5″, and 3″ tubes. Based on these findings, we suggest an optimal tube size of 2″ or smaller, considering a maximum flow rate of 1000 stbpd. Experimental measurements indicated a minimum sand transport velocity of 0.48 m/s, while steady-state models pointed to a requirement of around 0.4 m/s to prevent sand accumulation. Interestingly, our experiments revealed that OLGA underestimated the minimum sand transport velocity required to prevent sand accumulation. The study provides new insights into the dynamics of sand transport, emphasizing in particular the limitations of OLGA for coarser particles and inclined wells. The findings give engineers practical guidance for maximizing production and maintaining well integrity.