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IPA16-16-E

PROCEEDINGS, INDONESIAN PETROLEUM ASSOCIATION


Fortieth Annual Convention & Exhibition, May 2016

ALTERNATIVE SAND CONTROL OFFERING COST EFFECTIVE SOLUTION IN TUNU FIELD

A. A. Risatrio*
B. Muryanto*
F. Wahyudi*
R. Wijaya*
B. Styward*
H. A. Sinaga*

ABSTRACT confirming completion cost reduction. Further trials


are planned to confirm the robustness of sand
Development of the shallow reservoir in Tunu field, control and productivity.
Mahakam Block requires cost effective solutions to
produce multi layered sandy reservoirs. Gravel Pack INTRODUCTION
system has enabled production of thin layers with
multi zone single trip gravel pack system. However, The gas production from Tunu Field, operated by
the system has reached its technical limits in terms Total E&P Indonesie, has been producing since
of cost, number and spacing of completed zones and 1990’s. At the early development phase most of the
well deviation. production was coming from lower reservoirs.
Since mid 2000s, shallower layers have been
Developing an alternative sand control solution is contributing to compensate gas production decline.
required to produce small marginal reservoirs and The challenge to produce unconsolidated shallow
maximize recovery while maintaining robust sand layers is to deploy cost effective methods to
control. The alternative system should reduce maintain productivity while avoiding sand
completion time and allow for completion in high production on remote surface facilities.
departure well for producing hard to reach reserves.
Traditionally, Multi Zone Single Trip Gravel Pack
Shunt tube gravel pack system, shape memory (MZ-STGP) has been used to avoid sand production
polymer and Ceramic screen are considered as in Tunu Field. The system has proved to be reliable
emerging alternative solutions to cut sand control with 135 wells and 532 zones completed since
cost. Multi Zone Shunt tube screen will reduce 2006. However, MZ-STGP has technical limitation
completion time significantly due to the ability to in number of zones completed and total gross
perform simultaneous gravel pack pumping in a distance between the uppermost and lowest
single trip. In the other hand, shape memory reservoirs. It requires performing multiple trips or
polymer and Ceramic Screen will also reduce the bypassing small reservoirs deemed uneconomic.
completion time even further by removing the
necessity of gravel pack. To validate the use of the Shunt tube gravel pack, shape memory polymer,
three alternatives, trial in cased hole architecture and ceramic screen are proposed to tackle those
was planned. limitations. The systems could lead to a
significantly lower sand control cost by faster
Extensive work on well design was performed. completion operation and, in case for Geoform and
Completion design was optimized to protect ceramic screen eliminating cost for gravel pack
completions while maintaining acceptable pumping. To validate the concept, some trials in
productivity. Special clean up procedure was cased hole were conducted to test robustness of
established to avoid sand failure. these systems.

To date two wells have been completed using Shunt Shunt Tube Gravel pack system
tube system, four wells using ceramic screen and
one well with shape memory polymer. The success Shunt tube system is based on a typical multizone
of these initial trials gives a good base for single trip gravel pack system with the addition of

* TOTAL E&P INDONESIÉ 


shunt tube in front of each sand screen and cup centralizer serve as protector against debris or other
packer. The shunt tube will transfer the gravel junk during run in hole.
between zones while the cup packer is an isolation
packer run against the casing wall. The system One of the concerns for Ceramic SAS is the
reduces significantly the lower completion handling of the ceramic screen itself. Since Ceramic
assembly deployment duration. GP pumping is material tends to be brittle, extra precaution has to
performed simultaneously for several zones through be maintained during transport and running in hole.
single GP sleeve transported inside shunt tubes in Sudden movement and shock impact in the ceramic
front of every zone. screen needs to be minimized. Make-up of the
screens must be done with precaution not to damage
It achieves significant saving from completion ceramic jacket area with wrenches applied only on
operation and simultaneous pumping. the base pipe. While running in hole the tripping
speed also needs to be limited to 45 ft/min. Rotation
Two major drawbacks of this system are running on the screens needs to be avoided.
very long assembly with short shunt tube and
assuring gravel pack of every zone with only one To date, four wells consisting of 5 gas reservoirs
GP port. T-ST1 was the first pilot well combined have been completed using Ceramic Screens which
with standard GP operation.. Total length of shunt are described in Figure 4.
tube is 400 m with 3 GP zones targeted. Shunt tube
screen was equipped with integrated sliding sleeve Shape Memory polymer
door (SSD) to ensure selectivity while optimizing
operation time. T-ST2 well was 3 zone shunt tube The system basically is a downhole-screen structure
system second trial. At the time of the deployment, capable of self-expanding and conforming to the
T-ST2 was the longest shunt tube system in the borehole surfaces. It uses Shape Memory Polymer
world. (SMP) as materials that have the ability to return to
their original (permanent) shape after being induced
However logging result showed incomplete packing into a deformed state (temporary shape) by an
in front of upper zone despite good screen out and external stimulus.
restress during GP pumping. During analysis,
proppant movement was discovered even after Shape memory polymer saved 39 hours of rigtime
screen out and restress. from the relative simple deployment. Once the
downhole assembly deployed an activation fluid
Ceramic Sand Screens Design Principles was pumped through the tubing. Since the
activation fluid used for expanding the material is
flammable, some comprehensive and precautious
The design of ceramic screen consists of three
preparation is required for this system. The other
elements -- a stack of ceramic rings, two coupling
drawback of the shape memory polymer is the
elements and a fixing device to mount the assembly
difficulties to confirm the expansion of the material
to a tubular support. For the ceramic rings, sintered
once it is inside the well.
silicon carbide (SSiC) was chosen as material. SSiC
boasts an unique combination of properties,
The overall result from pilot phase confirms that
including excellent abrasion and corrosion
both ceramic screen and shape-memory polymer
resistance, low density, high hardness and high
can be combined with existing MZ-STGP system or
stiffness [reff Müssig, S., Wagner, S., Kayser, A.,
can be run combined with other alternative
and Wildhack, S. 2010].
solutions. The potential of the time saving and
overall completion cost saving is described in
To assure zone selectivity, isolation string was Figure 6.
deployed inside the lower completion assembly
with sliding sleeve positioned opposite to the Conclusions and Recommendations
screen. In addition, water swell packer was installed
below each ceramic screen assembly. The purpose Pilot results of MZ-STGP with shunt tube have
of swell packer is to reduce the void space below shown significant time saving. However,
the screen that eventually will minimize formation Mahakam’s soft reservoirs are challenging for
time of natural sand pack (NSP). A slip-on simultaneous pumping application. Reservoir
centralizer was installed above the screen to provide characteristics present difficulty to control GP
better centralizing. Both swell packer and proppant packing and can lead to poor proppant

 
coverage. Further trials with modification of shunt REFERENCES
tube design should be performed to avoid proppant
displacement after pumping. Risatrio, A.A., Muryanto, B.H., Wijaya, R.,
Jackson, R., Gundemoni, B.R., Cased Hole Ceramic
Ceramic screen and shape memory polymer offer Screen Cutting Completion Cost for Marginal
simple deployment and faster installation. However, Reservoir: Application in Tunu Field, Paper SPE
it is too early to draw a conclusion from alternative 176225-MS presented at APOGCE Conference held
sand control. Further monitoring of production and in Bali, Indonesia, 2015
optimization should be performed to ensure
favorable long term result.
Muryanto, B., Lavoix, F., Labeyrie, C., Wijaya, R.,
Combining the three solutions can give flexibility to Ji, Y., Roane, T., Hustache, H., Ayusta, P.,
optimize completion cost, completing marginal Albertson, E., Improving Operation Safety of Multi
zones and extending the well reach. Perfecting and Zone Single Trip Gravel Pack: Holistic Approach to
maturing these solutions will allow industrialization Minimize Well Control Risk in Mahakam presented
and give access to previously non-economical at OTC Conference, Houston, 2015
reservoirs.

ACKNOWLEDGEMENTS Laidlaw, D., Agee, D., Madyanova, M., Hustache,


H., Combination of Dual String Single Trip Multi-
The authors would like to thank SKK-Migas, Total Zone Completion Systems and High Rate
E&P Indonesie & INPEX for permission to produce Formation Pack as a Proven Completion
this paper. Additionally, the authors would like to Methodology for an Unconsolidated Reservoir:
thank Schlumberger, Baker Hughes and 3M Case Study Tunu Field. Paper SPE 155202
completion team for technical and operational presented at SPE Oil and Gas India Conference and
support throughout the course of the project. Exhibition held in Mumbai, India, 2012

 
TABLE 1

SUMMARY OF TRIAL RESULT OF SHUNT TUBE SYSTEM

Well Name T-ST1 T-ST2


Total Length 420 m 740 m
Number of zones 3 + 1 stack GP 3
Rigtime saved 45 hours 93 hours

TABLE 2

SUMMARY OF TRIAL RESULT OF CERAMIC SCREEN

TN-AA1 TN-AA2 TN-AA3 TN-AA4


Number of Zone 6 2 2 1
Zone with Ceramic 1 2 1 1
Number of trip 2 1 1 1

Rigtime saved 8 hours 41 hours 12 hours 40 hours

 
Figure 1 - Tunu Field geological cut and Typical MZSTGP completion

Figure 2 - MZ-STGP with short Shunt Tube and Cup Packer with T-ST1 and T-ST2 diagram

Figure 3 - Ceramic ring design and stacked ceramic rings providing for keystone slot shape

 
Figure 4 - Completion schematic on four Tunu wells with ceramic screen, TN-AA1, TN-AA2, TN-AA3,
TN-AA4

Figure 5 - Shape memory polymer and Completion Schematic for TN-T1

 
Figure 6 - Potential time saving and overall completion cost saving

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