PRO CEED IN G SIM PO SIUM N ASIO N AL IATM I 2001
Yogyakarta, 3- 5 O ktober 2001
SAND CONTROL FOR UNCONSOLIDATED RESERVOIRS
B. Kuncoro, B. Ulumuddin, & S. Palar
Unocal Indonesia Company
ABSTRACT
Unocal Indonesia has several producing fields with unconsolidated reservoirs. These reservoirs present a challenge in producing
oil and gas while controlling the sand production. Several methods have been tried with mixed results.
This paper will highlight the recent practices in sand control in Unocal Indonesia. The practices include expandable sand screen,
through-tubing gravel pack, horizontal well screen, plastic consolidation, etc. It will share Unocal experiences in the recent sand
control.
1. INTRODUCTION
Most fields in Unocal Operation offshore East Kalimantan
produce from Pliocene to middle Miocene-age Mahakam
delta sediment in which the reservoir rock is unconsolidated.
These sandstones consist of loose, fine to coarse, quartz grains
and dispersed clay. From widespread producing experience in
the deltaic environment, it is known that some wells produce
sand and others do not. Also many wells, which produced oil
or gas with no sand initially, start to produce large quantity of
sand when water production begins. This experience is
perhaps not surprising as sand control in the oil industry has
been a big issue for many years.
In developing sand control methods, either mechanical or
chemical method have been used. Mechanical method deals
with the design of screens, slotted liners and placement of
gravel packs. Technology today introduces expandable screen
completions for enhancing productivity. Chemical method
deals with the plastic/ resin system, and techniques of
applying them.
Gravel packing was a blanket practice for controlling sand
production since the mid 70’s in Unocal Indonesia producing
area of the Y field, because many of the unconsolidated
reservoirs were sanding up, cutting up tubular and surface
equipment. Recent practices in sand control are also
considered in most of offshore’s wells, including the
conventional, monobores and horizontal wells. Unocal has
tried many horizontal completions in East Kalimantan
utilizing wire-wrapped screen. Recent technique of
Expandable Sand Screen (ESS) has also been tried for open
and cased hole wells. Five wells have implemented the Thru-
Tubing Gravel pack (TTGP) in low-pressure single reservoir.
One well has tried a sand consolidation using resin-coated
technique.
2. CAUSES OF SAND PRODUCTION
The solid material which is produced from a well consists of
formation fines and load bearing sand1). The fines production,
which can not normally be prevented, is preferred over the
production of load bearing sand. Sand production will create a
problem if the surface equipment can not handle it, if the sand
blocks the tubing, or if the sand production detrimentally alter
the formation (i.e. collapsed formation).
Some well-known causes of sand production are listed below:
IATM I 2001- 08
2.1. Onset of water production.
There are 4 reasons on why sand production are worsened by
increasing water production 4) :
a. Capillary pressure holding sand grains are lost due to
producing water.
b. Flow frictional significantly increases due to more than
one phase flow.
c. High pressure gradient at the sandface due to higher flow
rate for a desired net production.
d. Water may dissolve cementing materials between sand
grains.
It is true that most of the East Kalimantan wells which
produce sand are preceded by the onset of water production.
However, it is noted that in some wells, no water production
was noted prior to the sand up. Therefore, other factors such
as the ones listed below might contribute to the causes.
2.2. Unconsolidated formation.
The cementation of a sandstone is typically a secondary
geological process and as a general rule, older sediments tend
to be more consolidated than newer sediments. This indicates
that sand production is likely from shallow, geologically
younger sedimentary formations such as the Low Resistive
Sequence in S Field or the Shallow and Deltaic Sequence in A
Field.
Unconsolidated formation refers to a formation in a fluid
state. Grain to grain contacts are rare. Any attempt to produce
formation fluid can result in production of large amounts of
sand with fluid. Poorly consolidated sandstone formations
usually have a compressive strength that is less than 1000
psi3).
2.3. Reduction of pore pressure.
Some reservoirs are believed to aid in the support of
overburden. Lowering the reservoir pressure creates an
increasing amount of stress on the formation sand itself.
Continuing reduction of reservoir pressure may cause the
overburden to subside and crush a poorly consolidated
formation and result in sand production and serious casing
damage.
As most reservoirs in this sequence are not supported by
strong water drive, their pressures are declining quite fast with
time and production. For example, some reservoirs in the
Sand Control for Unconsolidated Reservoirs
shallow sequences of the S field had been depleted to 3-4 ppg
EMW and prove to sand production.
2.3. High production rates.
The high production rate imposes excessive stresses on
unconsolidated formations. If the stress exceeds the formation
strength, sand production will commence. Increasing the
production rate is usually done for a high water cut well, in
order to maintain a desired rate of oil production.
It is empirically experienced in some East Kalimantan wells
that a threshold rate for sand production can be noted. Above
the said rate, sand will be produced. However, most of the
time, as the rate is below the economic rate, the wells have to
endure with the sand production to be economic.
Some authors7,8) discussed the presence of sand arches around
each perforation in the casing. An arch is a hemispherical cap
of interlocking sand grains that is stable at constant drawdown
and flow rate, preventing sand movement2). Initial arch size
was found to be a function of initial producing rate. The initial
arch size increases with increasing initial production rate.
Larger arches were resulted from higher flow rates. Changes
in flow rate or production shut in may result in collapse of the
arch, causing sand to be produced until a new arch form.
It is also possible to relate sonic and density log data to
estimate the maximum sand-free production rate from each
arch9). Arch faces must remain in place if no sand production
is to occur.
3. THE MECHANISM OF SAND PRODUCTION
The mechanisms of sand production are either grain by grain
attrition or small masses of sand breaking away10). Veeken et
al5) divides the types of sand production into three types:
Transient sand production, continuous sand production and
catastrophic sand production.
3.1. Transient Sand Production:
This refers to a sand concentration declining with time
under constant well production conditions. This is
usually observed during clean-up flow after perforating,
choke change, and water breakthrough.
3.2. Continuous Sand Production:
The tolerated sand cut level depends on operational
constraints with regard to erosion, sand disposal, etc.
3.3. Catastrophic Sand Production:
Events where a high rate of sand influx causes the well
to suddenly die.
For the transient and continuous sand production, some of the
continuously produced sand settles inside the wellbore and
increases the hold-up depth. However, it will take time for
sand-up to occur due to less sand production, especially if the
majority of the sand is transported to the surface. If all the
sand can be carried out of the wellbore, no sand-up will occur
and no sand control is required, provided that the surface
facilities can handle and process the sand production.
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B. Kuncoro, B. Ulumudin, S. Palar
In S field, several wells, completed without sand control
(gravel pack) have been continuously producing sand (0-1%)
for several years without sand-up. This can be attributed to the
flow ability to transport most of the produced sand out of the
wells.
However, sand production can seriously damage the reservoir
rock around the wellbore (i.e. collapse) and restress the
reservoir during sand control application might reduce the
permeability around the wellbore. Therefore, the best time to
apply sand control, if needed, is right at the beginning
together with the initial well design.
4. TYPES OF SAND CONTROL
There are many types of sand control, which are:
4.1. Mechanical Retention:
A good example of this type of sand control is gravel pack.
Formation sands are restrained from entering the wellbore.
The underlying principle for the mechanical retention is to
retain a certain portion of the formation material to prevent
the remainder from entering the wellbore1). Mechanical
retention uses screen and man-made sand to control formation
sand.
4.2. Plastic Consolidation:
The basic idea is to cement the formation sand with some
chemical such as epoxies, etc. The chemical is injected to
cover an area of several feet around the wellbore. Porosities
and permeabilities of the area around the wellbore will be
reduced once it is subjected to plastic consolidation.
4.3. Combination:
This type uses gravel pack as well as the plastic consolidation.
Resin-coated gravel pack is the good example of this
combination type.
5. RECENT PRACTICES OF SAND CONTROL
5.1. Horizontal Well Screen
Horizontal wells became popular to develop the shallow
reservoirs in most of Unocal’s fields in East Kalimantan as
drilling costs significantly reduce with experience. As sand
control is required in weakly consolidated to unconsolidated
sandstones, open hole screens have been the primary
completion method over the years. More than 50 horizontal11)
wells in Unocal Indonesia have been completed with wire-
wrapped screen without a gravel pack.
The benefits of horizontal screen completions are as follows:
• A field: enlarging drainage, reducing drawdown of gas
delivery and improving recovery of thin oil under gas cap
and water support.
• S field: managing a strong bottom/ edge water to reduce
coning and improving the sweep efficiency.
• Y field: enlarging reservoir drainage with viscous oil.
• M field: increasing recovery and reducing pressure
drawdown.
Sand Control for Unconsolidated Reservoirs
Typically, the wells were drilled from offshore platforms
across the highest part of the target reservoir. A real time log
was used to determine where the casing landing point, from
which a lateral section has to be placed. An open hole of 500-
1000 feet interval length11) with wire-wrapped screen is found
cost-effective application in maximizing contact to formation.
Eliminating gravel pack and minimizing screen-hole annulus
prevent hole collapse as well as reduce formation damage. In
general, the wire-wrapped screen completion was chosen as to
filter formation fine from the produced fluid, with the
assumption that formation material is continually being
deposited on the outer surface. In order for the screen to
function properly, it must provide high-sustained flow rates
without being eroded.
The screen is manufactured by wrapping a triangular shaped
(keystone) wire into a section usually referred to as a jacket
which the keystone shape minimizes plugging. The jacket can
be welded to a pipe base containing 70-140 holes per foot
which serves as a structural support and provides filtration.
The slot opening can also be wrapped to a specified width,
which is typically –0.002 to +0.001 inch15). Figure-1 shows a
typical wire-wrapped screen after Penberthy. Figure-2 shows
a horizontal well completion with wire-wrapped screen.
Field experiences around Unocal’s field area using wire-
wrapped screen completion for horizontal open hole have
been mixed. The success and failure seem to be related to the
quality of the formation, the screen completion procedures
and the way the well is brought on production (Table-1).
Since the screen functions as a filter, completion procedures
become critical issues, as it tends to plug. Drilling fluid and
hole size selection for screen completion presumably might
have been responsible for some failure (i.e. no production).
The other factors are probably water blocking, immediate
plugging, depleted pressure, or mechanical problems.
A more common experience has been that initial production is
good, but later screen plugging or erosion (screen cut) may
prematurely sand-up the well. However, most wire-wrapped
completions have been successful to mitigate sand problems
in unconsolidated reservoirs.
5.2. Thru-Tubing Gravel Pack (TTGP)
TTGP completions accomplish sand control by placing a
down-hole filter (screen) across the perforated intervals. This
filter forms when the gravel pack sand filters out the
formation sand and the screen filters out the gravel sand12). In
monobore or slim hole wells, screen is put in place by coiled
tubing unit.
There are two TTGP methods tried in A field. The pack off
method and the vent screen method basically pack perforation
tunnel and place gravel across it inside the 1.9-inch screen.
This gravel will form a flow barrier to stop fine sand
movement of unconsolidated sand.
Pack-off case
A well was re-drilled and completed as a monobore producer
in the 55-9 sand where the 3½-inch tubing is cemented and
perforated. The peak production was 1367 BOPD, 10% BSW,
GOR 1975 in April 2000. Afterward the well had been
declining rapidly to 419 BOPD, 44% BSW, in 7 months
before being shut-in due to sand-up. Sand control is
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B. Kuncoro, B. Ulumudin, S. Palar
recommended to recover the remaining oil in the 55-9
reservoir.
This technique utilizes coil tubing to foam wash sand across
the perforation. As the hole has been cleaned across
perforation, re-perforation with 12-18 SPF (shots per foot) big
hole guns is conducted. A 3½-inch bridge plug is set at least
10-ft below bottom perforation to properly place the pack-off
screen BHA (bottom hole assembly). Wire-wrapped screen of
12-20 gravel size is installed. Figure-3 shows an example of
pack-off method for TTGP applied.
Production history afterward shows a stabilizing rate of 600
BOPD, 45% BSW, GOR 500-2000 for 8 months.
Performance history is shown in Figure-4.
Unocal has used pack-off screen (single and dual screen)
method for three wells. Results from the method vary and
depend upon how sand stability had been damaged by well
production over time. In general, TTGP in monobore wells
applied seems to give a better sand control, as being cost
effective and increasing recovery, particularly in pressure
depleting oil reservoirs.
Vent screen case (dual screen)
This technique was tried in three wells completed in the 7-
inch casing of the unconsolidated Deltaic sandstones. One of
them was completed in October 1998, produced for less than
3 months before stopping production due to sand up.
The last well test recorded in January 1999 was 96 BOPD, 17
% BS&W, GOR 208 on gas lift. An inexpensive vent screen
sand control method was recommended to recover the
remaining marginal oil from the 54-0 sand, which can not be
economically justified using conventional gravel pack.
The procedure is the same as in the previous method. It starts
by foam washing sand to below perforation internals and re-
perforating with 12-18 SPF of big-hole guns. After setting 7-
inch MPBT (Mechanical Plug-back Tool) at some distance
below perforation intervals, this technique uses a small OD
through-tubing screen (strata-coil). The screen is placed to
cover the perforation zone with approximately 5-ft overlap on
top and bottom. A 60-ft blank pipe section is placed above
with a 10-ft vent screen on top of blank pipe.
This double screen assembly is then placed on bottom
utilizing coil tubing and set across the perforations in the
lower section. As the BHA has been properly placed, the
predetermined volumes of sand (slurry) is then pumped down
the coil tubing and around the double screen leaving about
100-ft of sand fill above the vent. The slurry is re-stressed by
pumping from the annulus to pack around the lower section of
the assembly. As screen out pressure is observed, the excess
sand is removed from around the upper (vent) screen section.
The well is then produced directly through the lower screen,
up the blank pipe and out the vent screen.
Coil tubing uses nitrogen to displace the completion fluid
from the well bore. Figure-5 shows the vent screen method
for TTGP. The well could produce back with the same rate as
before. Figure-6 shows the production performance TTGP
using the vent method.
This method appears to be not satisfactory when applied in 7-
inch wellbore compared with the 3½-in. monobore hole. Out
of the three 7-inch wellbores, only one is considered as good
Sand Control for Unconsolidated Reservoirs
producer. This well has given a constant oil production rate
for more than one year.
5.3. Plastic Consolidation
As the reservoir pressure depletes, sand production becomes a
problem to deplete reserves in a well with larger production
casing (i.e. 9-5/8 inch). Plastic consolidation offers another
alternate for restoring and enhancing the desire productivity.
This method basically is a technique of stopping sand
production by artificially bonding the formation sand grains
near the wellbore perforations into consolidated mass.
Because the treatment is designed to function on formation
sand, this method is usually limited to a zone of 10-20 feet
perforated intervals. 13)
Unocal has tried the resin consolidation treatment in one well
of the Shallow sequence of the A field. The well sanded up
while producing oil. Sand consolidation technique utilizing
coiled tubing for through-tubing workover and rigless
completion was chosen as an inexpensive option to recover
the remaining oil. Figure-7 shows the resin consolidation
treatment. The resin treatment in a well of the A field could
deliver approximately 400 BOPD initially from 10 feet thick
intervals of the shallow unconsolidated reservoir, 7-inch cased
hole well. It was then no longer produced as sand coated
found breaking and sanded up again.
5.4. Expandable Sand Screen (ESS)
The Expandable Sand Screen is a sand screen that is specially
designed to be expanded in the wellbore in order to fit the
wellbore diameter. The purpose of this expansion is to
eliminate the annulus between the wellbore and the screen
that generally could not be handled by the conventional sand
screen.
The ESS consists of 3 simple elements: expandable based
pipe, filtration media and expandable protective shroud.
Figure-8 shows an Expandable Sand Screen Construction.
The ESS base pipe is a robust Expandable Slotted Tube (EST)
which is capable of expanding up to 60% in diameter. The
base expandable slotted tube provides a large inflow area for
the produced fluids. Typically inflow areas for expandable
EST are 30-60 % depending on the expandable diameter of
the ESS 18).
The medium filter is attached to the base pipe using a process
that ensures the integrity and uniformity of the sand exclusion
apertures. The filter media overlap each other along the length
of the base pipe. These overlaps accommodate the increase in
circumference during expansion yet remains sand tight.
The outer protective shroud ensures the filter medium is not
damaged when running the screen in hole. It also acts as the
encapsulating layer, ensuring the filter media are tightly
sandwiched together following expansion.
Applications
The ESS can be installed either in cased hole or open hole
applications. In the cased hole application we have to
consider pre-packing the perforations tunnels. This depends
on reservoir sand distribution data. If the sand grain
distribution is highly uniform, the pre-packing of perforations
is not generally recommended, because smaller grains of sand
IATM I 2001- 08
B. Kuncoro, B. Ulumudin, S. Palar
will be transiently produced until a stable bridge of the larger
grains is established on the filter. For non-uniform sand
distribution, a long tile of fines and poor sorting would not
allow a stable bridge to be formed. Pre-packing of the
perforations is recommended for such applications. Big-hole
perforating charges are recommended for all cased hole ESS
installation in order to maximize the available screen inflow
area.
Openhole applications have a different set of considerations
because there is no casing, and no hydraulic isolation.
Fundamentally, by eliminating the annulus, ESS avoids the
wellbore collapse phenomenon seen with stand-alone screen
designs which leads to poor near-wellbore sand sorting,
reduce effective permeability and hence productivity loss.
An in-gauge hole section is important in order to maximize
the benefits of eliminating the annulus with ESS. Therefore,
this should be considered as an objective of the drilling
program and appropriate steps are required to achieve this.
Clean up of the filter-cake is also an important consideration
for openhole installations. However, this is dependent on the
drilling fluid used.
Unocal Indonesia has tried to use ESS in seven wells at three
different fields. The first batch installation was installed in the
Y field for two wells, while the second batch in the A field for
two wells and followed with third batch in the S field with
two wells. From these seven installations, four were
completed in the open hole, while the other three in the cased
hole. The summary of the ESS application is shown in the
Table-2. In term of sand control, the application of ESS in the
open-hole seemingly has better result compared to the cased-
hole.
Reservoir quality, pre-packing job and perforation density
contribute to success or failure of this completion, either in
the cased-hole or open-hole ESS application. For instance, the
failure of ESS installation in the cased hole is more likely due
to no pre-packing job on the perforation tunnel. The pre-
packing job in this reservoir is probably needed prior to
expanding of the ESS. In another case, even though the
reservoir quality is good (φ = 28%) but the reservoir pressure
was severely depleted.
The ESS-2, ESS-1 and ESS-4 wells are the examples of the
success case of ESS application in the open hole. The reasons
can be explained as follows:
• Good screen sizing for those three wells (230 micron weave
for ESS-2 and ESS-1 and 150 micron weave for ESS-4
wells)
• Have good reservoir quality (based on log interpretation)
• No major loss circulation problem during drilling operation
The failure case occurred in ESS-3 well. The well has a low
productivity and produces with trace sands. The major loss
circulation problem coupled with its low reservoir quality
probably the contributing factor this failure.
6. CONCLUSIONS
• There is no particular sand control method that can work
for all types of unconsolidated reservoirs. Experience with
Sand Control for Unconsolidated Reservoirs B. Kuncoro, B. Ulumudin, S. Palar

the same type of reservoirs in the same field proves to be
useful in the selection of sand control method.
• We can not shy away from using new technology despite
steep learning curve in the beginning. Applying new sand
control technology will broaden up our knowledge portfolio
of sand control methods. This will help in selecting a
particular fit for a particular reservoir.
• Need to talk about the design, the systematic planning,
implementation, and evaluation, the “batch” approach, etc.
REFERENCES
1. Penberthy, W.L. and Shaughnessy, C.M.: “Sand
Control”, SPE Series on Special Topic, 1992.
2. Carlson, J. et al.: “Sand Control: Why and How?”
Schlumberger Oilfield Review, October 1992.
15. Penberthy, W.L. :”Sand Control Completion Options
for Horizontal Wells in Soft Formations ”, Petroleum
Engineer International, February 1999, p. 49-54.
16. Soepyan, F., Palar, S., Kuntjoro, B.: “Sand Control in
Balikpapan Bay Fields ”, IPA, 26th Annual Convention,
May 1998, p. 97-107.
17. Zimmerman, J.C., Sargent, T.L., Coats, A., Clawson, G.:
“Applied High-Pressure Coiled-Tubing Technology
Solves Resin Sand Problem in a Gulf of Mexico High
Pressure Gas Well”, OTC paper No. 8527, 1997.
18. The use of ESS as Sand-Control Solution for
Multiple-Zone Completions, Weatherford Completion
System , February 2000.

3. Baker Inteq’s Seminar: ”Completion Technology for Table-1

Unconsolidated Formations ”, Jakarta, June 1995. Recent Completion in East Kalimantan

4. Morita, N. et al.: “Parametric Study of Sand Field Total Active Non-prod

Production Prediction: Analytical Approach”, SPE Wells Wells Wells
Paper No. 16990. Field A Oil 26 23 3
Field A Gas 20 17 3
5. Veeken, C.A.M. et al.: “Sand Production Prediction Field S 16 14 2
Review: Developing an Integrated Approach”, SPE Field M 5 4 1
Paper No. 22792, 1991. Field Y 11 11 0

6. Morita, N. and Boyd, P.A.: “Typical Sand Production

Problems: Case Studies and Strategies for Sand
Control”, SPE Paper No. 22739, October 1991.

7. Tippie, D.B. and Kohlhaas, C.A.: “Effect of Flow Rate

on Stability of Unconsolidated Producing Sands ”, SPE
Paper No. 4533, 1973.

8. Hall, C.D. and Harrisberger, W.H.: “Stability of Sand

Arches: A Key to Sand Control”, Journal of Petroleum
Technology, July 1970, p. 821-830.

9. Stein, N. et. al.: “Estimating Maximum Sand-Free

Production Rates From Friable Sands for Different
Well Completion Geometries”, Journal of Petroleum
Technology, October 1974, p. 1156-1158.

10. Otis Corporation: ”Sand Control Handbook”, Dallas,

1990.

11. Vo, D.T., Waryan, S., Dharmawan, A., Susilo, R.H.,

Wicaksana, R. :”Lookback on Performance of 50
Horizontal Wells Targeting Thin Oil Columns,
Mahakam Delta, East Kalimantan”, SPE paper No.
64385, October 2000.

12. Freiman, O.L., and Johnson, K.J. :”Use of The Dual-

Screen Thru Tubing Sand Control Method”, SPE
paper No. 28698, October 1994.

13. Slimhole/ Monobore Technology Guidelines, Unocal

Spirit Energy, October 1998.
14. Sparlin, D.D., Hagen, Jr, R.W. :”Controlling Sand in a
Horizontal Completion”, World Oil, November 1988,
p. 54-60.

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Sand Control for Unconsolidated Reservoirs B. Kuncoro, B. Ulumudin, S. Palar

Table-2
ESS Installation In Unocal Indonesia-Balikpapan

Figure-1
A typical wire wrapped screen design
and performance is shown
Figure-4
An example Pack-off production after TTGP

Figuire-2
Horizontal well completion with Wire-wrapped screen

Figure-5
Vent screen method for TTGP.

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Sand Control for Unconsolidated Reservoirs B. Kuncoro, B. Ulumudin, S. Palar

Figure-6
An example production performance TTGP
with Vent method

Figure-3
Pack-off Method for TTGP

resin-coated sand

Figure-8
Figure-7
Expandable Sand Screen Construction.
Resin Consolidation in wellbore

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