IPA18-337-E
PROCEEDINGS, INDONESIAN PETROLEUM ASSOCIATION
Forty-Second Annual Convention & Exhibition, May 2018
DO-IT-YOURSELF GRAVEL PACK APPLICATION IN TARAKAN, INDONESIA
Alexis Ariwibowo*
Muchammad Rizal Alfaqih*
ABSTRACT
Sandstone formations in the Mamburungan Field of
Tarakan Island, North Kalimantan have a history of
sand production especially from shallow gas
reservoirs. Gravel packs using third party services
have been proven to extend production lifetime and
increase cumulative production. However, the
remote location of Tarakan Island and cost of the
gravel pack job has limited application with third-
party services which must be mobilized from far
away. The Operator, PT. Medco E&P Indonesia, has
developed its own gravel pack, nicknamed Do-It-
Yourself or DIYGP, based on techniques and
procedures which rely mostly locally-manufactured
tools in order to reduce cost and so extend
application of gravel packs to previously
uneconomic candidates. So far the DIYGP has been
applied per design in just one well with a cost
reduction of over 90% compared to third party jobs.
And, after five (5) months with cumulative
production of 17.7 MMscf, the well continues to
produce sand-free. Payout time for the DIYGP for
this particular well is one and a half (1.5) months.
However, testing indicates a significant positive
skin, and efforts are underway to improve the
technique and extend it to other candidates.
INTRODUCTION
Sandstone formations in Tarakan Island,
especially shallow gas formations that are above
1,000 meters have a history of producing sand. The
effects could be sand piling in the wellbore, choke
abrasion, flow line leaks, separator fill-up, etc.
Attempts to overcome these problems by applying
sand control have been done over the years with
various results and include things like stand-alone
screens, gravel packs, and surface sand handling
with no downhole sand control. A summary of
selected adjacent and reference wells that have
produced in similar gas reservoirs and the various
sand control techniques is displayed in Table 1. As
shown in Table 1, sand control using gravel pack
in well H-3 has been historically proven to
* Medco E&P Indonesia
successfully overcome sand problem in Tarakan.
Whereas the absence of sand control or using a
stand alone sand screen would result in decreasing
production lifetime as shown in the other wells in
Table 1 without gravel pack.
Unfortunately, the location of Tarakan island itself
makes most of the potential gas formations
uneconomically viable to produce due to high
gravel pack cost. This high gravel pack cost is
mainly caused by high mobilization and
demobilization cost to and from Tarakan island,
which could be more than the cost to perform the
gravel pack services itself. This paper will describe
how designing, manufacturing, and installing
gravel pack using mostly local resources can be the
solution for a more cost efficient way to produce
gas reservoirs, without taking away the quality and
technical advantage of a service provided gravel
pack. The designed DIYGP will be installed in
well M-9.
DESIGN OF GRAVEL PACK
Gravel and Screen Design
Gravel and screen design is made based on sand
sieve analysis of sand produced from wells which
produce from formations above 1,000 meters. The
results of the sieve anlaysis are shown in Table 2.
Based on the table, the 50% value on the
cumulative mass distribution plot (D50) is
approximately 180 µm with uniformity coefficient
D40/D90 of 4.62. In this design, gravel pack sand
size is calculated in the range of 5 to 6 times the
D50 and also keeping in mind the design used in
gravel pack well H-3. Therefore, 16/40 sand size
and 404 µm screen slot width was determined to
be used in gravel pack well M-9.
Gravel used in this DIYGP sourced from Juwata
natural sand in Tarakan. The natural sand was
sized using a 16/40 mesh sieve screen. While sand
screen was purchased from one of the gravel pack
supplier.
Tool Configuration Design
Normally a gravel pack tool configuration would
consist of a screen, blank pipe, and gravel pack
packer complete with a multi-position working tool.
The multi-position working tool is essential in gravel
placement due to its ability to alter the circulating
path during placement and pumping of gravel. Since
a multi-position working tool was unavailable, and
could not be manufactured locally, the DIYGP tool
configuration was modified to accommodate its
function, without jeopardizing the quality and
functionality of the whole gravel pack configuration.
DIYGP tool configuration for M-9 can be seen in
Figure 1, consist of seal-bore packer, screen, blank
pipe, float valve, and mule shoe. In addition to the
gravel pack tools assembly, Figure 2 shows the
seal bore & seal stinger assembly which was made
and installed on top of cross over (inside blank
pipe). This seal bore & seal stinger assembly is
critical to ensure the gravel slurry could flow from
the work string to the annulus of the screen.
Without this assembly, gravel would fill up inside
the screen, instead of behind the screen, and the
whole gravel pack would have failed. The function
of the seal bore & seal stinger assembly replaced
the multi-position working tool which is normally
used in gravel pack job services.
The seal packer and seal bore & seal stinger
assembly were designed and manufactured locally
in a vessel specialized machinery workshop.
Sketch drawings complete with dimensions were
discussed in advance with manufacturer to assess
the visibility of the work. During the
manufacturing process, which took approximately
2 weeks, company representative was assigned to
supervise the process.
The seal packer is designed complete with setting
tool, and once the seal packer is set complete with
the gravel pack configuration, the setting tool can
be retrieved. The seal stinger is then run to latch
into the seal bore to create a seal between the
inside of the tubing string and the tubing annulus
inside the screen. This will prevent sand building
up inside the screen, and divert the flow path to go
through the float valve, mule shoe, and annulus of
the screen.
By using DIYGP, installation would require two (2)
runs. The first run is to set gravel pack screen and
seal packer assembly, and the second run is to run the
seal stinger for gravel placement. Compared to a
service-provided gravel pack, which is done in a
single trip, two (2) run installation process is a slight
disadvantage. However, since the daily rate cost for
this DIYGP installation in M-9 is relatively low, the
additional operation time cost was less significant
compare to the overall cost saving made using
DIYGP.
Installation and Gravel Placement Procedure
Prior to setting the seal packer and gravel in place, a
cement plug is set approximately 9-meters below
perforation interval. The cement plug acts as a
landing base for the gravel pack screen and it enables
seal packer to be set in place.
Installation and gravel placement procedure are
described as follow:
 RIH with a drill pipe string and DIYGP tool
configuration, which consist of mule shoe, float
valve, crossover complete with seal bore, blank
pipe, screen, and seal packer, using a packer
setting tool to top of cement
 Set the seal packer and gravel pack assembly by
rotating setting tool clockwise until torque
1,000-ftlb. Ensure using tally that the screen is
in front of perforation. Once seal packer is set,
pick-up test by over pull 6,000-lb
 Release packer setting tool and POOH setting
tool
 RIH seal stinger to top of seal bore, circulate and
record circulating pressure
 Sting in seal stinger to seal bore, circulate and
record circulating pressure (there should be an
increase in circulating pressure)
 Mix gravel slurry with concentration of 1 – 1.5
ppg gravel, or 1 – 1.5 lb of gravel per gallon
slurry* with formula as follow:
10-bbl FW + 0.25-ppb Caustic soda + 40-ppb
Bentonite gel + 11-sack Natural 16/40 sand (@
5-gal, 62.7-lb)
* - The range of gravel slurry concentration was
based on previous experience at H-3 which had
a premature screen out above 2 ppg.
 Pump gravel slurry and displace with tubing
volume with pumping schedule as follow:
Slurry volume : 12-bbl
Displace volume : 9.6-bbl
Surface line volume : 1-bbl
 Total pumping volume : 22.6-bbl
Flow path of gravel slurry could be seen in
Figure 3.
RESULT
Gravel Pack Tool Installation
For well M-9, the base cement for landing the gravel
pack tools is at 652.6 meter KB, and the perforation
interval is from 642 to 643 meter KB. Therefore, the
gravel pack tool configuration was installed as
shown in Table 3. Once the gravel pack tool was in
place, the seal packer was set with 1,000 ft.lb right-
hand torque, and a pick-up test was conducted with
overpull 15,000 lb., then the packer setting tool was
released and the work string was pulled out of the
hole. All indication and parameters showed the
gravel pack tool was set according to design.
Gravel Placement
The seal stinger assembly was run until top of blank
pipe for a circulation test. The circulation test was
conducted to record initial circulating pressure prior
to sting in and after sting in into seal bore. This step
was necessary to ensure the seal stinger was working
properly and the integrity of the circulation path
through the float valve and screen annulus. The
recorded circulation pressure are shown below:
Sting out position : 200-psi
Sting in position : 240-psi (shows circulation
path through float valve adds 40-psi pressure drop)
After ensuring the gravel pack tools were in pumping
position, the gravel slurry was mixed with using a
company-owned cementing unit and with
parameters:
 Slurry volume : 12 bbl
 Slurry density : 9.8 ppg
 Excess : 18 %
 Gravel concentration : 1.4 ppg
The gravel slurry volume of 13 bbl was pumped with
pump pressure 300-psi, continued by 8 bbl
displacement volume until achieving a gravel pack
pressure at 1,000-psi, with the pressure limited by the
potential for hydraulic fracturing. After re-
confirming the pack pressure to 1,000-ps, the string
was pulled out of the seal stinger and excess gravel
slurry was reversed out inside string. Post job
calculation estimates that gravel placement achieved
92.2 % of total gravel volume with top of gravel
behind screen at 637 meter KB.
Installation of completion string and testing result
confirms that dry gas was be produced without any
sand problem to occur. Well M-9 has been
producing with no evidence of sand production and
the gas was being produced for 177 days until the
wellhead pressure declines to equal gas system
pressure. Although the well has successfully
produce Gas without sand problem, there are
improvements to be made as pressure survey test
show that the gravel pack has a permeability of
only 11 mD and skin factor of 36. These are the
parameters that should be addressed in next
DIYGP design.
Cost wise, significant savings were made during
the whole gravel pack design, manufacture, and
installation process. This DIYGP method of
performing simple gravel pack with locally
designed and manufactured key downhole
equipment reduced cost by more than 90 %
compare to previous third party gravel pack jobs.
This cost reduction was mainly due to the absence
of mobilization & demobilization cost, service cost
and a significant reduction in gravel pack tools and
consumable materials.
There are three (3) additional well candidates for
DIYGP application, which are currently on
subsurface review. Based on the lessons learned
during DIYGP installation in M-9, there are two
(2) main improvements to be done in future job.
First is to use a well-rounded ceramic sand, and
second is to use fresh water as gravel carrier fluid.
By using fresh water as a carrier fluid, gravel
concentration would have to be 1-ppg.
CONCLUSIONS and RECOMMENDATIONS
1. The DIYGP using local resources for design
and manufacturing of key equipment and
consumable materials reduced cost by over
90% compared to previous third party jobs.
2. Well M-9 has produced for five (5) months
sand free since the DIYGP with total
production of 17.7 MMscf which gives a
payout of one and a half (1.5) months.
3. DIYGP is currently being considered for three
(3) other wells in the Hakebabo and Sesanip
field. Based on lessons learned, the DIYGP
can be improved by using well-rounded
ceramic sand and use clear fresh water as
carrier fluid for the gravel.
ACKNOWLEDGMENTS
The author would like to thank PT. Medco E&P
Indonesia, SKK Migas, and Direktorat Jenderal
Migas for their permission to publish this paper.
We also acknowledge the valuable contribution of
members of Tarakan Asset field operation and
engineering. Last but not least, the authors would
like to show their appreciation for the support of
Medco’s Drilling and Completions Department
and the Workover & Well Services Department.
http://gekengineering.com/Downloads/Free_Downl
oads/Sand_Control_Overview.pdf
Halliburton. 2004. Design of Service for Gravel Pack
Service HKB-03
Halliburton. 2008. Design of Service for Gravel Pack
Service Mengatal 2008-1
Purwaka, Edi. 2013. Work Over and Well
Completion.

REFERENCES TRACS International training material. February

2009. Completion Design
George E. King Engineering. 14 March 2009. Sand
Petrowiki. 2017. Gravel Pack Design.
Control Method.
http://petrowiki.org/Gravel_pack_design

 
 TABLE 1

SUMMARY OF SELECTED ADJACENT AND REFERENCE WELLS THAT HAS PRODUCED IN

SIMILAR GAS RESERVOIRS IN THE MAMBURNGAN AND HAKEBABO FIELD, TARAKAN,
KALIMANTAN

Well Formation Oil / Gas Sand Control Lifetime

M-10 700MZ Gas Stand alone screen 135 days

M-17 700MZ Gas None 99 days

H-3 745MZ Gas Gravel pack

H-4 790MZ Gas Stand alone screen +/- 7 days

TABLE 2

(A) TABLE AND (B) GRAPHIC FOR SIEVE ANALYSIS OF PRODUCED SAND IN
FORMATIONS ABOVE 1000 METER FROM [NAME] FIELD

Grain
Sieve No Size Weight Weight Cum. Weight
(mesh) (μm) (gram) (%) (%)
50 300 130.61 43.54 43.54
60 250 6.95 2.32 45.85
70 212 7.23 2.41 48.26
80 180 4.98 1.66 49.92
100 125 92.18 30.73 80.65
170 90 14.79 4.93 85.58
230 63 38.79 12.93 98.51
270 53 2.36 0.79 99.30
>270 40 2.11 0.70 100.00
TOTAL 300 100
(a)

SIEVE ANALYSIS
100
CUMMULATIVE WEIGHT (%)

80

60

40

20

0
400  300  200  100  0 
GRAIN SIZE (µm)
(b)

 
 TABLE 3

GRAVEL PACK TOOL CONFIGURATION FOR DIYGP IN WELL M-9.

Top Lower Depth Depth

Description Connection Connection Length (m) (mKB) (mKB)
(mKB) (mKB) Top Bottom
Upper Seal Packer - BTC 0.225 634.4 634.62
Lower Seal Packer BTC 4" NUE 0.875 634.62 635.50
Screen GP 4" NUE 4" NUE 9.970 635.50 645.47
Blank Pipe 4" NUE 4" NUE 6.065 645.47 651.53
Cross Over 4" NUE 3-1/2" EUE 0.120 651.53 651.65
Float Valve 3-1/2" EUE 3-1/2" EUE 0.275 651.65 651.93
Mule Shoe 3-1/2" EUE - 0.675 651.93 652.60

 
  Description
Seal Pac ker

Screen Gravel Pack

Blank Pipe

Cross Over (with seal bore)

Float Valve

Mule Shoe

Figure 1 - Designed gravel pack tool configuration

 
  Description
Seal Stinger (connect to work
string and latch to seal bore)

Blank Pipe

Seal Bore

Cross Over
Figure 2 - Designed seal bore & seal stinger assembly

 
 Gravel slurry flow path:
1. Inside Work string  
2. Through seal stinger and seal bore 
3. Through float valve and mule shoe 
4. Enter annulus between gravel pack screen 
and production casing 
5. Carrier fluid will flow through inside screen, 
and gravel will be filtered and remain in 
annulus 
6. Carrier fluid flow between inside seal 
packer and work string up to surface 
through annulus work string 

Pumping gravel slurry should always be in sting

in position

Figure 3 - Flow path of gravel slurry during gravel placement