CFD-DEM study on the blocking conformation of pre-filled sand control screen by layering method

Preventing screen blockage due to sand poses a significant challenge. The article combines computational fluid dynamics (CFD) and discrete element method (DEM) to establish a fully coupled four-way interaction model. A sophisticated size particle injection model was established, taking into account the particle size distribution (PSD) characteristics of the formation. A layering method was used to study the sand control behavior of a highperformance pre-filled screen. The study also quantitatively investigated the impact of factors such as median sand size (D50), screen structure, and fluid velocity on both wellbore-screen annulus and internal screen plugging patterns. The findings reveal that the sand retention rate within the wellbore-screen annulus exceeds 93.8 %. The risk of pre-filled screen blockage is minimized when the ratio of gravel diameter to sand diameter falls within the range of 3.3-5. At a gravel filling rate of 97 %, fine sand predominantly moves radially, resulting in a low risk of blockage at the screen's entrance layer, thereby favoring oil and gas production. In cases with elevated fine sand content, it is advisable to maintain a production flow rate below 3 m/s to mitigate localized erosion damage caused by increased pressure resulting from screen blockage. This model holds significant importance in optimizing completion tools and production parameters.