gravel pack machine specification

Addressing Critical Gravel Packing Challenges: Precision, Downtime, and Cost Control

Inconsistent gravel pack placement leads to well sanding and costly remediation. Manual placement methods often result in density variations that compromise formation stability. Equipment failures in remote locations create production delays with significant daily revenue impact. Are you managing these operational risks while maintaining project timelines and budget parameters? The right gravel pack machine specification is fundamental to resolving these issues, directly influencing completion quality, non-productive time (NPT), and total cost of ownership.

Product Overview: High-Precision Gravel Packing Unit

This system is a skid-mounted, high-pressure slurry blending and pumping unit designed for controlled gravel pack operations. Its core function is to accurately mix proppant with carrier fluid and place it downhole with consistent density, forming a stable filter to prevent sand ingress into the wellbore.

Operational Workflow:

1. Proportioning: Dry gravel is fed from a hopper into a continuous mixing tub at a precisely controlled rate.
2. Slurry Mixing: The gravel is blended with a gelled carrier fluid to create a homogeneous slurry.
3. High-Pressure Injection: A positive displacement pump delivers the slurry at calculated pressures and flow rates to the downhole service tool and screen assembly.

Application Scope: This equipment is engineered for cased-hole and open-hole gravel packing in oil, gas, and water wells, typically in onshore and shallow offshore environments. It is compatible with various proppant types including silica sand and ceramic media.

Limitations: System performance is contingent on supporting equipment capacity (e.g., fluid storage, proppant supply) and is designed for specific pressure and hydraulic horsepower ranges.

Core Features: Engineered for Performance and Reliability

The following features are central to our gravel pack machine specification, each delivering a distinct operational advantage.

• Automated Density Control System | Technical Basis: Continuous real-time mass flow and Coriolis meter feedback | Operational Benefit: Maintains slurry density within ±0.1 ppg target, eliminating human error in mixing | ROI Impact: Reduces screen-out incidents by up to 25%, saving an average of 16 hours of rig time per event

• Positive Displacement Triplex Pump | Technical Basis: Three-piston design with hardened fluid end components | Operational Benefit: Provides steady, pulse-free flow for uniform pack placement and handles high solids concentrations | ROI Impact: Extends maintenance intervals by over 40%, lowering lifecycle costs and parts inventory

• Modular Skid Design | Technical Basis: Bolt-together sub-assemblies with standardized interfaces | Operational Benefit: Enables rapid deployment, site reconfiguration, and simplified transport between remote locations | ROI Impact: Cuts mobilization/demobilization time by 30%, accelerating project start-up

• Advanced Data Logging Package | Technical Basis: Integrated sensors recording pressure, density, and rate | Operational Benefit: Provides verifiable job data for quality assurance and post-job analysis | ROI Impact: Creates an auditable trail that mitigates disputes and informs future design improvements

• Corrosion-Resistant Fluid Path | Technical Basis: Lined piping and stainless-steel wetted parts | Operational Benefit: Withstands corrosive completion brines and abrasive slurries, ensuring long-term integrity | ROI Impact: Minimizes unplanned downtime due to component failure in aggressive service environments

Competitive Advantages: Quantifiable Performance Metrics

Industry testing demonstrates clear performance differentials when comparing standard units to our defined gravel pack machine specification.

Performance Metric	Industry Standard	Our Solution	Advantage
Slurry Density Consistency (variance from target)	±0.5 ppg	±0.1 ppg	80% Improvement
Mean Time Between Failures (MTBF) - Pump Circuit	1,200 hours	2,000 hours	67% Improvement
Average Job Mobilization Time (on-site)	8 hours	5.5 hours	31% Reduction
Proppant Placement Efficiency (per stage)	~90%	~98%+	Significant reduction in waste

Technical Specifications

Adherence to a precise gravel pack machine specification ensures operational compatibility. The following data outlines the standard configuration.

• Capacity & Ratings
  • Maximum Working Pressure: 5,000 psi / 345 bar
  • Maximum Flow Rate: 8 BPM / 1.26 m³/min
  • Proppant Hopper Capacity: 400 ft³ / 11.3 m³
  • Maximum Proppant Concentration: 15 PPA
• Power Requirements
  • Prime Mover: Tier 4 Final Diesel Engine, 600 HP
  • Hydraulic System Power: Independent circuit for auxiliary functions
• Material Specifications
  • Pump Fluid End: Ceramic-lined with tungsten carbide valves & seats
  • Mixing Tub & Flow Line: Abrasion-resistant steel with replaceable liners
• Physical Dimensions
  • Skid Footprint (L x W): 20 ft x 8 ft / 6.1 m x 2.4 m
  • Transport Weight (dry): ~28,000 lbs / ~12,700 kg
• Environmental Operating Range
  • Ambient Temperature Range: -20°F to +120°F / -29°C to +49°C
  • Designed for operation in harsh desert and maritime conditions.

Application Scenarios

Unconventional Gas Well Completions | Challenge:

A multi-well pad campaign experienced frequent screen-outs due to inconsistent slurry density from older equipment, leading to an average of $75k in remediation costs per incident.
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Solution:
Implementation of a new gravel pack machine specification focused on automated density control.
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Results:
Zero screen-outs over the subsequent 15-well campaign; achieved a consistent pack factor exceeding 1.45 lb/ft²; reduced average pumping time per stage by 22%.

Offshore Water Injector Wells |

Challenge:
Sand production in water injector wells was causing damage to downhole equipment and reducing injection rates by over 30%, requiring frequent workovers.
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Solution:
Deployment of a high-pressure gravel pack unit meeting strict offshore size/weight limits while delivering precise placement.
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Results:
Restored injection rates to design specifications; eliminated sand-related failures for over three years; extended well service life with no unplanned interventions.

Commercial Considerations

Investing in the correct gravel pack machine specification involves evaluating capital outlay against long-term operational savings.

• Pricing Tiers: Equipment is available via direct purchase or long-term lease agreements tailored to project scope.
• Optional Features: Enhancements include remote operation capability via fiber optic link, enhanced data analytics software packages, or high-pressure pump ends rated to 7,500 psi for extreme-depth applications.
• Service Packages*: Comprehensive plans include scheduled maintenance, guaranteed parts availability with rapid delivery schedules (<48 hrs), and optional on-site technical support during critical operations.
  Financing Options**: Flexible capital expenditure solutions are available through partner financial institutions.

Frequently Asked Questions (FAQ)

What are the power interface requirements for this gravel pack machine specification?
The unit is self-contained with its own diesel power pack. For rigs requiring electric drive, we offer an alternative model with a HV electric motor compatible with standard rig power.

How does this equipment integrate with our existing sand handling and fluid systems?
Standardized flange connections and control system interfaces are designed for integration with most modern well service setups. Our engineering team conducts a pre-deployment review to ensure compatibility.

What training is provided for our operators on the new control system?
We provide comprehensive on-site operator training covering routine operation, basic troubleshooting, and safety procedures over a standard three-day period at commissioning.

Can you quantify the expected reduction in non-productive time?
Field data from similar deployments shows an average NPT reduction of between 15-25% directly attributable to improved reliability and reduced screen-out frequency.

What are the lead times for critical spare parts?
Our global parts distribution network guarantees shipment of critical spares within 24 hours from regional hubs under our premium service agreement.

Does your technical support extend beyond initial commissioning?
Yes. We offer tiered support packages providing round-the-clock access to technical experts via phone or satellite link during active operations worldwide