9/22/2011
Cold Heavy Oil Production with Sand Workshop Calgary September 21, 2011
For More information
Visit The OTS (Oilfield Technical Society) Heavy Oil Science Center
Lloydminster
Visit www.lloydminsterheavyoil.com References are on the CD Visit www.kirbyhayes.com
Recon CHOPS Workshop Calgary Sept 21, 2011
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Kirby Hayes
runs his own company, Kirby Hayes Incorporated (KHI), which represents several corporations offering services and productions primarily involved in heavy oil production extensive background in cased hole wireline has co-authored several technical papers, patent applications, conducted seminars, short courses, workshops and presentations on wide-ranging topics of interest to heavy oil producers
Recon CHOPS Workshop Calgary Sept 21, 2011
4
Recon CHOPS Workshop Calgary Sept 21, 2011
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Integrated Production Services Recon Petrotechnologies Ltd. Wavefront Technology Solutions Inc.
Ace Oilfield Endurance Technologies Alberta Innovates Technology Futures
Recon CHOPS Workshop Calgary Sept 21, 2011
Thank you Presentation contributions:
Ron Sawatzky, ARC Bob Mottram, Weatherford Rob Morgan, Harvest Murray Tluchak, Bonavista Ryan Rueve, Nexen Floyd Isley, CNRL Rick Walker, Devon Jerry Schoenroth, Husky Mike Kremer, Husky Cedric Gal, CAG Consulting
Dave Love John Newman Janelle Irwin Maurice Dusseault, U of W Ace Oilfeild Schlumberger G-Chem IPS Wavefront And others
Recon CHOPS Workshop Calgary Sept 21, 2011
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Outline
CHOPS – an overview Perforating for heavy oil – the issues Break Alternate completions Interventions examples Lunch Next steps prior to thermal or solvent EOR processes Interesting log examples Discussion Recon CHOPS Workshop Calgary Sept 21, 2011
Cold Production “Other things being equal, the maximum recovery of oil from an unconsolidated sand is directly dependent upon the maximum recovery of the sand itself” William H. Kobbe, in Trans. A.I.M.E., Vol. LVI, pp. 799-830 February, 1917 (New York)
Recon CHOPS Workshop Calgary Sept 21, 2011
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How Big Is It?
Canada & US consume ~ 20 MBOD ~ 2,600,000,000,000 barrels in place (heavy oil and oil sands) in Canada If we achieve 30% recovery… 100% of current consumption for 100 years So…
why fight over Middle East Oil? production problems are being solved
Recon CHOPS Workshop Calgary Sept 21, 2011
SAGD
CSS CHOPS
Before 1990
Cost per Barrel ($)
Operating Costs
}
}
cold
+ steam
Recon CHOPS Workshop Calgary Sept 21, 2011
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Recovery Efficiency 60 50
20 10
SAGD
}
}
0
CSS
30
CHOPS
Before 1990
Recovery (%)
40
cold
+ steam
Recon CHOPS Workshop Calgary Sept 21, 2011
Could we get there? 1,200,000
Production (bopd)
1,000,000
800,000
600,000
400,000
200,000
0 Jan-70
Jan-75
Jan-80
Jan-85
Jan-90
Jan-95
Jan-00
Jan-05
Jan-10
Jan-15
Jan-20
Recon CHOPS Workshop Calgary Sept 21, 2011
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Technology is the Key
What are the technologies?
Thermal Processes
steam, SAGD, electrical heating
Chemical Processes
solvent, upgrading
full value chain enhancement
Displacement Processes
need to manage energy equation
enhanced floods
water, polymer, chemical
Pink Smoke and Marbles???
Recon CHOPS Workshop Calgary Sept 21, 2011
35 Billion Barrel Resource The industry needs to improve recovery factors
6.5%
17.6%
2.1%
73.8% Cumulative Recovery
Remaining Recoverable
Remaining Resource
Incremental Technology Wedge
Slides courtesy of Rob Morgan, Harvest
Recon CHOPS Workshop Calgary Sept 21, 2011
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Heavy Oil & Bitumen Production Western Canadian Crude Oil Production Source
Production (bbl/day)
Oil Sands Mining
760,000
Oil Sands In Situ
330,000
Conventional Heavy
500,000
(Cold Production)
(230,000)
Conventional Light
500,000
TOTALS
2,190,000
Production statistics at December, 2006 Sources: Alberta Dept. of Energy, NEB
Recon CHOPS Workshop Calgary Sept 21, 2011
Deltaic Depositional Environment
The Mississippi Delta
A satellite photo of the Ganges Delta in India
Recon CHOPS Workshop Calgary Sept 21, 2011
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Exploration
In general exploration for CHOPS is easy in Lloydminster Best tool is offset mapping and production – high existing well density lends itself to good mapping 3D seismic is the norm Success rate is high (> 85%) Large regional sands are dependable and predictable Channels are a bit more tricky in terms of traps and water content – but big prizes
Recon CHOPS Workshop Calgary Sept 21, 2011
Heavy Oil Leases
There are three basic configurations for a CHOPS well
Vertical Slant Directional
Recon CHOPS Workshop Calgary Sept 21, 2011
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Cold Production Field Examples Producer
PanCanadian
Mobil
Suncor
Amoco
Texaco
Formation
Mannville
Mannville
Clearwater
Clearwater
Mannville
Field
Lindbergh, Frog Lake
Celtic
Burnt Lake
Elk Point
Frog Lake
80
87
70-80
10
5-11
11-15.2
10
1,200 to 3,000
40,000 (dead)
2,000 to 55,000
20,000 to 50,000
3.8
2.8-3.4
Oil Saturation (%) Gas/Oil Ratio (std m 3/m 3) Live Oil Viscosity (mPa s) Pressure (MPa)
3,000 to 10,000 4
3.3
3.3
Permeability (darcy)
1.5-2.5
0.5-4.0
2.0
API gravity
12-14
Net pay (m)
14
Porosity (%)
32
1.0-5.0
12
11
3-5
20
11-14
4-11
33
34
34
33
5 – 25 m3/day
Typical field oil production rates
Recon CHOPS Workshop Calgary Sept 21, 2011
Cold Production Lloydminster-Area Cold Production Blocks Block
Producing Well Count #
Oil Production (m3/day)
Avg Rate per Well (m3/day)
Lloyd
3,667
21,757
5.9
Lindbergh
1,322
8,348
6.3
Cold Lake
600
4,486
7.5
SW Sask
306
2,220
7.3
TOTALS
5,895
36,811
6.2
Production statistics at December, 2001
Recon CHOPS Workshop Calgary Sept 21, 2011
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Cold Production Oil Production Rate Estimates 100 5 m net pay 2,500 kPa draw down 7 in wellbore diameter 200 m far-field radius
with sand
Oil Rate (m3/day)
10 without sand
1 Effective Permeability 1 darcy
3 darcy
10 darcy
30 darcy
100 darcy
300 darcy
0.1
0.01 100
1,000
typical for cold production
10,000
100,000
Oil Viscosity (mPa.s)
Recon CHOPS Workshop Calgary Sept 21, 2011
CHOPS continued sand production at cuts 0.5%
depth ~ 400 - 600 m thickness ~ 2-7m
Development of high permeability channels – “wormholes” much greater reservoir access Large, local drawdowns at ends of channels high pressure gradients – gas exsolution Substantial increase in oil rates Successful commercial process Recon CHOPS Workshop Calgary Sept 21, 2011
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Example of a Wormhole on Surface
Recon CHOPS Workshop Calgary Sept 21, 2011
Far Field Reservoir Drainage
Andrew Squires and Earl Jensen
Recon CHOPS Workshop Calgary Sept 21, 2011
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Stimulating Sand Production
Where does new failure occur?
Near well
In reservoir
at tip of wormhole network
enhances drainage
Near well
Reservoir
at edge of cavity
neutral or negative impact on inflow
Recon CHOPS Workshop Calgary Sept 21, 2011
Completion Objectives
To initiate sanding: Initial sand production history of a well affects its long term productivity
Recon CHOPS Workshop Calgary Sept 21, 2011
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Cold Production Field Oil Production Rates 25
Oil Rate (m3/day)
20 with sand
15
10 without sand
5
0 0
360
720
1,080
1,440
Production Time (days)
Recon CHOPS Workshop Calgary Sept 21, 2011
Field Behavior Typical Good Well 25
1.0 Field Oil Rates Field Water Rates Field Sand Rates
0.8
15
0.6
10
0.4
5
0.2
0 0
360
720
1,080
Sand Rate (m3/day)
Oil Rate (m3/day)
20
0.0 1,440
Production Time (days)
Recon CHOPS Workshop Calgary Sept 21, 2011
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25
Aggressive Sand Production
1.0 Field Oil Rates Field Water Rates Field Sand Rates
0.8
15
0.6
10
0.4
5
0.2
Sand Rate (m3/day)
Oil Rate (m3/day)
20
Foam Job for 6-33 Series1
100%
90%
0 0
360
720
1,080
80%
Series2
Series3
Series4
0.0 1,440
Production Time (days)
Achieved during a stable foam operation on a new complletion In 40 hours produced: 117m3 sand 222m3 oil 90m3 water
Percentage Recovered (%)
70%
60% 50%
40%
30%
20%
10%
0% 07/11/19 07/11/19 07/11/19 08/11/19 08/11/19 08/11/19 08/11/19 08/11/19 09/11/19 09/11/19 09/11/19 09/11/19 99 9:36 99 14:24 99 19:12 99 0:00 99 4:48 99 9:36 99 14:24 99 19:12 99 0:00 99 4:48 99 9:36 99 14:24
Recon CHOPS Workshop Calgary Sept 21, 2011
Stages of Development
Sand Matrix Failure Wormhole Growth Sand and Fluid Transport matrix failure when: p
pc
inflow Imposed
wormholes partially filled with sand
p
wormholes filled with sand
Recon CHOPS Workshop Calgary Sept 21, 2011
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Sand and Fluid Transport
Tip of wormhole network to well EITHER: Plug flow in filled wormholes
high produced sand cut ~ 20-40%
Mobile Sand
Recon CHOPS Workshop Calgary Sept 21, 2011
Sand and Fluid Transport
OR: Stratified flow in open wormholes
low produced sand cut ~ 1-2% Flowing Oil
Mobile Sand
Immobile Sand
Recon CHOPS Workshop Calgary Sept 21, 2011
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Wormhole Growth
Recon CHOPS Workshop Calgary Sept 21, 2011
Wormhole Growth
Recon CHOPS Workshop Calgary Sept 21, 2011
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Field Predictions Dynamic Wormhole Growth
Recon CHOPS Workshop Calgary Sept 21, 2011
Wormhole Growth Wormhole Structure wormhole cast after removal
imprint left when cast was removed
loose sand 20 cm
10 cm
Tensile failure bands
Recon CHOPS Workshop Calgary Sept 21, 2011
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Wormhole Growth Wormhole Configuration
36 cm
Top Orifice Sand Pack
30 cm
Bottom Orifice
80 cm
Recon CHOPS Workshop Calgary Sept 21, 2011
Wormhole Growth Wormhole Configuration
24 cm Top Orifice Sand Pack
30 cm
Bottom Orifice
80 cm
Recon CHOPS Workshop Calgary Sept 21, 2011
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Wormhole Growth Wormhole Configuration
44 cm
Top Orifice Sand Pack
30 cm
Bottom Orifice
80 cm
Recon CHOPS Workshop Calgary Sept 21, 2011
Wormhole Growth
Critical Pressure Gradient
expansion of gas bubbles
Growth Rate
reduced by foamy oil
increases with pressure gradient
Diameter
increases with drained region open (sand-free) area likely less than 10 cm in diameter
Recon CHOPS Workshop Calgary Sept 21, 2011
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Wormhole Growth
Interaction
wormholes compete for drainage Darwinian behaviour some grow, some wither
Recon CHOPS Workshop Calgary Sept 21, 2011
Sand Matrix Failure
Formation Strength
unconsolidated sand low cohesive strength 5 – 20 kPa fines content increases strength capillary pressure capillary cohesion high oil viscosity dynamic strengthening slight cementation substantial strength increase
Recon CHOPS Workshop Calgary Sept 21, 2011
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Field Implications
Operate wells at low enough pressure to allow continuing sand production Wormholes tend to grow first and predominantly in weakest sand and toward highest pressure gradient Wormholes don‟t necessarily grow from each perforation – dependant on sand strength Wormholes usually stable
Recon CHOPS Workshop Calgary Sept 21, 2011
44 Petrovera, Elk Point Battery
Recon CHOPS Workshop Calgary Sept 21, 2011
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Foamy Oil
Large numbers of persistent gas bubbles in oil Generated by depressurization of live heavy oils
Recon CHOPS Workshop Calgary Sept 21, 2011
Bubble Growth and Gas Transport Dynamic Partitioning Oil Phase Dissolved Gas
Small Bubbles
Immobile
Gas Phase
Large Bubbles
Connected Bubbles
Recon CHOPS Workshop Calgary Sept 21, 2011
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Bubble Growth and Gas Transport and/or expansion
Increasing time,
Microbubbles Small bubbles ( pore throat)
Flow with oil
Large bubbles ( pore throat)
Immobile
Interconnected bubble clusters
Free gas flow
Recon CHOPS Workshop Calgary Sept 21, 2011
Field Implications
Operate wells at low enough pressure to obtain rapid local gas exsolution Surprisingly high ultimate recoveries, due to high apparent critical gas saturations Large blasts of gas when growing wormhole network and growing zones of interconnected bubble clusters connect
Recon CHOPS Workshop Calgary Sept 21, 2011
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Conclusions Courtesy of Ron Sawatzky AITF
Gas Production
Oil Production
dissolved gas likely only source of produced gas for 2 wells additional external gas source may exist in 2 wells (petrophysics indicates source present, flow path uncertain) reasonable rates can be maintained at fairly high producing GOR: i.e. ~ 10-20 initial GOR
Draw Down
oil production rates and recovery enhanced by rapid draw down
Recon CHOPS Workshop Calgary Sept 21, 2011
When Cold Production Fails
Well
perforation plugging shale / coal failure collapse or blockage casing failure
Reservoir
well bore sands off
Near well
wormholes plug, collapse, stop growing watering out gas breakthrough permeability reduction from fines, formation debris, wax precipitation and wasted solution gas
Important to understand for diagnosis
Recon CHOPS Workshop Calgary Sept 21, 2011
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Complex Flow
Phases - gas, water, oil , sand and solids Variables
Mobility Cuts - time Viscosity (oil) – time – depth Sources of water and gas in the drainage geometry Sources (gas) – free or solution?
Recon CHOPS Workshop Calgary Sept 21, 2011
Where Blockage Can Happen
Recon CHOPS Workshop Calgary Sept 21, 2011
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Debris Causing Blockage Material
Formation
Pyrite Shale Coal Chert Asphaltenes Waxes Complex sands, silts and clays
Other
Drilling mud Cement Perf debris
Possible to remedy with workover/s
Will probably re-occur
Recon CHOPS Workshop Calgary Sept 21, 2011
Example of Debris
Recon CHOPS Workshop Calgary Sept 21, 2011
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Sand plugging, bridging and arching
From gravel pack literature:
Tendency for bridging = k Dsand grain/Dgravel
Capacity for unrestricted flow = k` Dperf/Dsand grain
Dr.Tariq Schlumberger
Studies concluded ratios from 3:1 to 16:1 hole size to flowing solid size
Recon CHOPS Workshop Calgary Sept 21, 2011
Coal
Can Be a water source, check offsets
28
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Carbonate Example
Note SP and Pe response Recon CHOPS Workshop Calgary Sept 21, 2011
Recon CHOPS Workshop Calgary Sept 21, 2011
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Recon CHOPS Workshop Calgary Sept 21, 2011
Gamma Ray (GR)
Can be useful to identify shale collapse Warning: GR is statistical… don‟t read too much into subtleties if the logs show different character - the borehole has changed (casing & cement)
Recon CHOPS Workshop Calgary Sept 21, 2011
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Compensated Neutron Log (CNL) Diagnostic Log Note GR and N Porosity Differences CNL Diagnostic Log Open Hole Log
Cased Hole Neutron Logs (CNL)
Can be useful to identify coal shifts Warning: N is statistical… don‟t read too much into subtleties if the logs show different character - the borehole has changed (casing & cement)
Recon CHOPS Workshop Calgary Sept 21, 2011
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50/50 Deep Penetrator(DP) / Big Hole (BH) or eXtra Big Hole (XBH)
Politically correct – why didn‟t you use …? How thick is the cement sheath? – use manufacturer‟s model to determine penetration through the sheath – usually the cement sheath is not that thick Can you shoot through drilling fluid loss damage? Increased volume of traumatized zone? Sacrifice of flow area
Recon CHOPS Workshop Calgary Sept 21, 2011
Traumatized zone DP vs. XBH
Damaged zone XBH DP
Recon CHOPS Workshop Calgary Sept 21, 2011
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A New (Better) Configuration Than 50/50
26 Shots Per Meter (SPM) – 20 XBHs and 6 DPs 1/3 DP by 2/3 XBH 26spm Or 2:1
Less sacrifice of flow area Consistent with production performance data New - suppliers need lead time
Recon CHOPS Workshop Calgary Sept 21, 2011
Penetration versus compressive strength Penetration increases Charge
Target Steel
Rock < + -1000 psi compressive strength
Unconsolidated sand
Jet dispersion increases - penetration decreases Recon CHOPS Workshop Calgary Sept 21, 2011
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Recon CHOPS Workshop Calgary Sept 21, 2011
Recon CHOPS Workshop Calgary Sept 21, 2011
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Recon CHOPS Workshop Calgary Sept 21, 2011
Recon CHOPS Workshop Calgary Sept 21, 2011
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Casing and Cement Issues
Un-supported casing and cement is more likely to fail Do you perforate through collars?
Not recommended for thermal operations Depends on how thick the zone is
many don‟t
Recon CHOPS Workshop Calgary Sept 21, 2011
Current Trend Is Not To Shoot Through Collars Overburden
Probable casing failures
Completely failed region Do not perforate on the same horizontal plane in environments where this occurs
Recon CHOPS Workshop Calgary Sept 21, 2011
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Example of perforation damage to unsupported casing
Recon CHOPS Workshop Calgary Sept 21, 2011
Before
After
No severe damage from perforating
37
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Re-perforating Trends
Not popular ‟70s Bob Hayes “ Do we need more holes or are we just shaking things up?” Early ‟80s +- 10% successful Mid ‟90s optimizations with PCPs – 90% successful 2000 – casing and cement damage!! 2005 – missed pay and stimulation
Recon CHOPS Workshop Calgary Sept 21, 2011
Perforating Debris
Perforating debris from a 127mm 6 meter 26 spm DP / XBH gun Debris magnets are recommended
Recon CHOPS Workshop Calgary Sept 21, 2011
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Questions and Discussions
77
Extending Cold Production Applications
Stepping out from core heavy oil region
NW ~ sands weaker, oil more viscous SE ~ sands stronger, oil less viscous Kuwait, Alaska, Venezuela, Columbia, Albania, Argentina
Broader variation in reservoirs
heavy oil sands are not uniform differences occur over many scales
field to field pool to pool zone to zone
interval to interval
well to well
Recon CHOPS Workshop Calgary Sept 21, 2011
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Heavy Oil Completions
Can we throw out the cookie cutters? Alternate cookie cutters (methods)
Methods specific to the reservoir
Recon CHOPS Workshop Calgary Sept 21, 2011
The cookie cutter:
Perforate aggressively under balanced
Tight phasing, big hole, high shot density Most of the zone
Rapidly clean out with Pump To Surface (PTS), bailer or put on production with a Progressive Cavity Pump (PCP) Produce aggressively with PCP with as low as possible fluid level
30% of CHOPS wells fail Recon CHOPS Workshop Calgary Sept 21, 2011
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Shale Spalling De-pressurized shale from large draw down causes tiny particulate shale debris Buffer Layer
Establish a buffer layer Recon CHOPS Workshop Calgary Sept 21, 2011
Minimize shale spalling
Strategy for reducing risk
identify a buffer layer below shale to be not perforated thickness of buffer layer may depend on thickness of zone maintain a conservative draw down and avoid well bore trauma
Recon CHOPS Workshop Calgary Sept 21, 2011
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Shale Collapse
Recon CHOPS Workshop Calgary Sept 21, 2011
Casing Failure and Shale Collapse
Stable pillars
Recon CHOPS Workshop Calgary Sept 21, 2011
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Casing Failure and Shale Collapse
Strategy for reducing risk
perforate balanced or slightly under balanced perforate less aggressively with no more than 120 ,180 or 0 phasing slowly increase pressure draw down until production is initiated produce at a constant draw down until risk of destabilizing near well region becomes small (i.e. wormhole network is growing away from well) stable pillars harder to establish and maintain in thicker zones and are easy to establish between laminations steady draw down propagates worm hole growth of the weakest sands
Recon CHOPS Workshop Calgary Sept 21, 2011
Laminate pay example
Shale
$400k in rubble workovers Recon CHOPS Workshop Calgary Sept 21, 2011
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Laminate Pay Collapse
4.0 m perforations -104 shots
Recon CHOPS Workshop Calgary Sept 21, 2011
Laminate Pay Collapse Fragmentation
Extraneous water path
Recon CHOPS Workshop Calgary Sept 21, 2011
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Laminate Pay Collapse •17 SPM •0 degree phasing •Or just perforate the permeable lenses
Less density/number and fewer vertical planes less break up of shale laminations or alternate perforating means
Recon CHOPS Workshop Calgary Sept 21, 2011
Penetrators
Mill a 25.4mm window in casing Drill a 25.4mm, 2 meter horizontal hole Tool is controlled and activated by changing circulation rates and presuures Minimizes cement and shale fragmentation Overcomes drilling and fluid loss damage
Recon CHOPS Workshop Calgary Sept 21, 2011
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Example #2
Penetrated 8 x 1” holes at 90 o
Recon CHOPS Workshop Calgary Sept 21, 2011
Example #2 Production
Well watered out Discontinuous shale?
Recon CHOPS Workshop Calgary Sept 21, 2011
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Penetrator conclusions
Sustained production was achieved with a minimum of holes and flow area Proper clean up was achieved with chemicals and 24 -36 hour PTS operations
Recon CHOPS Workshop Calgary Sept 21, 2011
Cost Comparison Courtesy of Ryan Rueve, Nexen Pump to Surface (PTS) (with Tubing Conveyed Perforating (TCP) vs Perforating While Foaming (PWF) (TCP)
PTS (4 days with Rig) Rig (38 hrs) $13,680 Consultant $3,000 PTS Tool $2,500 Pressure/Vac $1,500
Total PTS costs $20,680
PWF (3 days with Rig) Patented Rig (29 hrs) $10,440 Consultant $2,250 Foam Unit $8,000 Pressure/Vac $2,200 Total PWF costs $22,890
Extra cost to PWF is approx $2,200. This is saved by less workovers caused by sand in months after the completion. Costs not included above are: perforating, tubing, rods, pump, etc. These items are the same in both scenarios.
Recon CHOPS Workshop Calgary Sept 21, 2011
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Nexen Cactus Lake Field R28
R27W3 E
F
8
Located 130km South of Lloyd in SK Reservoir Properties 9
10
11
S
12
8
G
G
FI E
E U
A
S
T36
S U
G
G
5
4
E I
E J
D
E E S U E M
E
A
29
G E
S
E
E E
S
J E E E
S
E
E
E
S E
E
S
S E
E
E
S
E
UE
S
6
S
S
E
E
E
E
S D
E
E
E
J E
S
E
I
I
E
E
S
E
S
G
S
E
K J
E
E
S
E
E
E
E
E E E
S
E
S
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E E
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S
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G
E
S
E
E
27
E
E S
S
E
E
I
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S
E
S
E
E S
S
G
I
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S
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G
S
U E
32
31
E
G
A
E A
G
L G
A
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I
26
D E A
E
E
E
•Density @ 15ºC = 965kg/m3 E
5
S
E
T36
S
E
36
S
E
E
S
S
35
DD D E ED
S
S
25
29
30
G
K J
G
T35
G
•Viscosity @ 30ºC = 500cP E
S
S
E
E
E
A
K
E
I
K
I
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G
E
•Porosity: 30-33% 22
A
U
23
24
K 20
19
E
S
E I
S
•Gravity: 16API E
E
S
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E
E
I
21
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JU
S
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E 28
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S
E S
S
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A
34
G
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I
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•~850 mKB (80m Sub Sea)
A
33
I
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S
G
A
S E E
UI
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•Bakken/Basal Mannville
F
I
G
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3
I
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32
E
G
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7
E
E
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G
K
G
•Permability: 2,000-4,000 md
A
I A
G
U R28
R27W3 Map Software by IHS Energy
Recon CHOPS Workshop Calgary Sept 21, 2011
Sand Cut Comparison of PTS & PWF
30
Sand Cut (%)
25 20 15
PTS
10
PWF
5 0 D1 621
C927
D727
B733
A836
C531
D522
Recon CHOPS Workshop Calgary Sept 21, 2011
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Filtered data 3 vs 3 wells – first month Average Monthly Oil Production for Fields By Completion Nexen PWF Wells
Nexen PTS Wells
Offset Wells
900
Cumulative Monthly Oil Production (m 3)
800
700
600
500
400
300
200
100
0 0
5
10
15
20
25
30
Months Since Completion
Recon CHOPS Workshop Calgary Sept 21, 2011
31/09 PTS
Recon CHOPS Workshop Calgary Sept 21, 2011
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21/07 PWF
Recon CHOPS Workshop Calgary Sept 21, 2011
Economics of more aggressive completions:
3 wells verses 3 wells for the 8 months after the first month The aggressive competed wells produced 4850 m3 more oil
Recon CHOPS Workshop Calgary Sept 21, 2011
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Observations From Data
Take it with a grain of salt especially the filtered data Excellent period of production PWF wells are to the outside of the pool (good and bad) PTS well 3.1 meters of perforations did quite well
Recon CHOPS Workshop Calgary Sept 21, 2011
Perturbation
Definition:
Positive or negative pressure change Can be as minute as varying the hydrostatic head from reciprocating pumps OR As large as massive pressure changes from foaming and the use of propellants (i.e. 60 MPa)
Recon CHOPS Workshop Calgary Sept 21, 2011
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Pressure Perturbation Limits
Dissipates rapidly as it propagates from the wellbore Viscosity prolongs pressure rise and fall time Friction losses occur along permeability channels
Recon CHOPS Workshop Calgary Sept 21, 2011
Drainage Geometry Conformance Average Daily CSE Sand Production / Well 25 Well Sample 0.35
0.3
0.25
m3
0.2
0.15
0.1
0.05
0
Why Do Continuous Sand Extraction (CSE) (CPTS) Pumps Produce More Sand ??? 1
2 Before
During
3 After
Recon CHOPS Workshop Calgary Sept 21, 2011
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CSE surge pump CSES
Canadian Patent 2,232,948
Recon CHOPS Workshop Calgary Sept 21, 2011
De-stabilizing sand bridges Negative well bore pressure perturbation
Overburden pressure
Perforation
or pore throat
Recon CHOPS Workshop Calgary Sept 21, 2011
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De-stabilizing sand bridges Positive well bore pressure perturbation
Overburden pressure
Perforation or pore throat
Recon CHOPS Workshop Calgary Sept 21, 2011
CSES
3 Mth Cumulative M3 of Oil
Comparison of 8 Wells Showing Production 3 Mths Before and 3 Mths after Tool Installation 3000 2500
2000 Includes 3 wells that were Shut In Prior to insertion Avg 4m3/d
1500 1000
500 0 1 Before
and
2 After
Recon CHOPS Workshop Calgary Sept 21, 2011
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Drainage Geometry Conformance Steady draw down worst case scenario
Lower pressure gradient laterally more stability
Greatest pressure gradient at tip
Steady pressure gradient
Intact formation
Drainage Geometry Conformance Intact formation
Fluctuating pressure gradient
Perturbed draw down
Intact formation
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Drainage Geometry Control
Perturbations conforms drainage Steady draw down propagates worm hole growth of the weakest sands
Recon CHOPS Workshop Calgary Sept 21, 2011
Drainage Geometry Control
Perturbations conforms drainage
Perturbations dissipate rapidly Employ immediately after completion
Recon CHOPS Workshop Calgary Sept 21, 2011
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Continuous Sand Extraction with surge Tool (CSES) Applied on Completion – Drainage Geometry Conformance
Advantages
Needs to be applied upon completion
Pumping equipment is capitalized The pumps can economically rebuilt in extreme sand cut environments The surge action enhances sand failure – conforming wormhole initiation and destabilises bridging Surge action only effects near well
Study in progress 3 new completions are being equipped with CSESs
Recon CHOPS Workshop Calgary Sept 21, 2011
Example of Downhole Pressure Perturbation With CSES
Recon CHOPS Workshop Calgary Sept 21, 2011
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35.00
30.00
Well 06D-20 Average production - 3.46m3/d
Pump Change
Completion PCP
Offset PCP example – 3.46m3/d average 100 90
80
60
20.00
50 15.00
40 30
10.00
20 5.00
BS&W (%) & Sand Cut (%)
70
Gross Fluid (m³/d)
Gross Oil (m³/d)
30-Jan-2011
1-Mar-2011
0
30-Dec-2010
30-Nov-2010
30-Oct-2010
10 -
30-Sep-2010
Production And Load Fluid (m³/d)
25.00
Net Oil (m³/d)
Recon CHOPS Workshop Calgary Sept 21, 2011
100 90 80
25.0
20.0
15.0
70 60 50 40 30
10.0
BSW (%) & Sand Cut (%)
Production And Load Fluid (m³/d)
Pump Change CSES
30.0
Pump Change PCP
CTU
35.0
CTU CTU
Completion
CSES Applied on Completion – 7.33m3/d average 20% sand cut Well 10B-20
20
5.0
Gross Fluid (m³/d)
Gross Oil (m³/d)
0 1-Mar-2011
30-Jan-2011
30-Dec-2010
30-Nov-2010
30-Oct-2010
-
30-Sep-2010
10
Net Oil (m³/d)
Recon CHOPS Workshop Calgary Sept 21, 2011
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CSES Applied on Completion - 6.74m3/d avg 66 % sand cut
35.00 30.00
100
80
25.00
60
20.00
BS&W (%)
Production And Load Fluid (m³/d)
40.00
120 Pump Service
Completion Pump Change CTUCTU Pump Change
45.00
Pump Change CSES
Pump Change - Temp PTS
Well 11B-20 50.00
40
15.00 10.00
20
Net Oil (m³/d)
0 1-Mar-2011
30-Jan-2011
30-Dec-2010
Gross Oil (m³/d)
30-Nov-2010
30-Oct-2010
Gross Fluid (m³/d)
30-Sep-2010
31-Aug-2010
31-Jul-2010
1-Jul-2010
-
31-May-2010
5.00
Recon CHOPS Workshop Calgary Sept 21, 2011
Questions and Discussion Recon CHOPS Workshop Calgary Sept 21, 2011
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Pump Problems?
Bridging in the Annulus Bridging in tubing
Plugged off inflow
Plug off at intake
Recon CHOPS Workshop Calgary Sept 21, 2011
Possible Solutions:
Bridging in annulus
Loading and continuous loading Reciprocating tubing pumps Coil tubing the annulus Others?
Plug off at intake
Loading and continuous loading Flush by Scope flush by Scope foam head Service rig – circulate down, sand line bail , tubing bail or foam clean out Charge/booster pump Extended rotors Paddle rotors BHP landing Depth Gizmo’s Tail joints Perforated joints Perforated tag bars Hollow rods Hollow rotors Multi intake PCPs CSE – ETU through THIGK valves Others?
Bridging in tubing
Smaller ID tubing Sand suspension chemicals Loading and continuous loading Flush by Coil tubing clean out Downhole gas separators Others?
Inflow Blockage
Loading Chemicals Stable foam stimulation Scope foam head Re-perforating Circulating Perforation wash Bailing / swabbing Sebree tool Propellant stimulation Abrasi-Jet, Penetrators Reciprocating tubing pumps CSES Others?
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Decline Rates for Diagnostics
Catastrophic
Mechanical Shale collapse Near well bridging
Gradual
Loss of foamy oil drive Flow impairment from load fluid Formation bridging
A week to months
Hours to a week
Recon CHOPS Workshop Calgary Sept 21, 2011
Approaches to Cold Heavy Oil Production: Workover Practices and Strategies March 15th, 2000 Tropical Inn – Lloydminster AB
M. Dusseault, K. Hayes, M. Kremer, C. Wallin
Recon CHOPS Calgary Sept 21, 2011
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The Tools Reviewed in the Workshop
Loading Continuous loading Circulating Flushes and superflushes Swabbing Sand line bailers Tubing bailers Select perf washes and perf cleaning Coil tubing and CTU flushes Pump to surface Portable PTS
Continuous PTS Re-perf Chemical treatments Propellant stimulation Stable foam clean outs (tubing) and stimulations Coil tubing foam clean outs Abrazi jet Proppant/Hydraulic fracturing Pressure pulsing
Recon CHOPS Workshop Calgary Sept 21, 2011
Stuff Not Reviewed in the Workshop
Mechanical remedies list Sebree tool Scope tool CTU/ flush units Gas management Sand management CSE with surge tools Balls checks for PTS Others?
Completion strategies
Shale strategies PAPWF Delayed water encroachment
Combined and staged approach Others?
Recon CHOPS Workshop Calgary Sept 21, 2011
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Staged Approach
Minimize risk
Diagnose, confirm, determine the extent of the problem Treat and evaluate treatment Re-treat or attempt a different treatment Evaluate Produce with a different production strategy Abort when necessary Example: Severe Inflow Blockage Program (SIBP)
A work in progress
Recon CHOPS Workshop Calgary Sept 21, 2011
Post Workover Production Strategies
Change production rates Change pumping fluid level and/or annular gas pressure Change pumping equipment Start or modify load program And so on, and so on … Congruent with workover strategy
Recon CHOPS Workshop Calgary Sept 21, 2011
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The Pitfalls:
Cookie cutters and magic pills Without proper diagnosis, too frequently Flush Production Flavor of the week and trends The lure of the latest and greatest Successes – misplaced credit Too rapid or slow application – tracking Complacency Changing too many variables Lowered one servicing cost but increasing another Wrong diagnosis – wrong conclusion (that doesn‟t work)
Recon CHOPS Workshop Calgary Sept 21, 2011
The 80/20 Rule
Spending 80% of the time working on 20% of the production Can we make good wells better?
Recon CHOPS Workshop Calgary Sept 21, 2011
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Canadian Patent 2,232,948
Recon CHOPS Workshop Calgary Sept 21, 2011
Dilation/failure by pressure Positive well bore pressure perturbation
Intact formation
Recon CHOPS Workshop Calgary Sept 21, 2011
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Dilation/failure by pressure Overburden pressure
Negative well bore pressure perturbation
Intact formation
Recon CHOPS Workshop Calgary Sept 21, 2011
Negative Perturbations Naturally More Conformed
Energy is virgin reservoir pressure More and stronger perturbations are better Recon CHOPS Workshop Calgary Sept 21, 2011
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Live Oil Viscosity 60,000
Viscosity (mPa.s)
50,000
40,000
30,000
20,000
10,000
0 0
1,000
2,000
3,000
4,000
5,000
6,000
Pressure (kPa g)
Recon CHOPS Workshop Calgary Sept 21, 2011
Loss of Solution Gas
Reservoir heterogeneity Asymmetric drainage geometry from wormhole growth Blockages caused by formation debris Water and/or gas breakthrough Casing venting during production interruption or production suspension
While producing the more mobile portions of the reservoir, the less mobile become more so
Recon CHOPS Workshop Calgary Sept 21, 2011
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Near Well Bore Blockage Weakest sand
Viscosity increases
Oil and sand production
Ex-solving gas
Ex-solving gas
Recon CHOPS Workshop Calgary Sept 21, 2011
Near Well Bore Blockage
Depleted Zone
Treatment Path of Least Resistance and Fluid That Is NOT Where the Problem Is
SCHMAG Dead Oil Recon CHOPS Workshop Calgary Sept 21, 2011
68
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SIBP Example – 11-23
Mid Oct „05 executed SIBP Cutter stock was pulsed to treat SCHMAG Fluid level rose Foam circulation and surging produced debris and oil operation continued for 3 days Installed CSES to de-stabilize debris and sand bridges Producing 9 m3/d with 16 joints of fluid
Recon CHOPS Workshop Calgary Sept 21, 2011
Diagnostic Logs for 11-23 OH GR
Diagnostic GR
Recon CHOPS Workshop Calgary Sept 21, 2011
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Production Data for 11-23
Recon CHOPS Workshop Calgary Sept 21, 2011
Production Data for 11-23
20
Post CSES Oil Production Rate (m3/d)
16
12
8
4
0 0
1
2
3
4
5
Production Time (months)
Recon CHOPS Workshop Calgary Sept 21, 2011
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Another Staged Intervention C1-18
Chemicals were placed by a perf wash tool to treat SCHMAG and left 7 days to soak Sebree tool and bailing were used to remove debris from the well bore and near well area over a 2 day period
Recon CHOPS Workshop Calgary Sept 21, 2011
Incremental Production for C1-18 During Intervention 25
Equivalent Calendar Day Production Rate 32.8 m3/d
Cum Oil Production (m3)
20
15
10
5
0 0
3
6
9
12
15
Production Time (hours)
Recon CHOPS Workshop Calgary Sept 21, 2011
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Production Data for C1-18 10
Oil Production Rate (m3/d)
8
Staged Intervention 6
4
2
0 0
6
12
18
24
30
Production Time (months)
Recon CHOPS Workshop Calgary Sept 21, 2011
Questions and Discussions
144
72
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Chemical and/or fluid stimulation
Should be done with pressure perturbations
Enhances formation access Adds energy to the reaction Dislodges blockage mechanisms Initiates particulate movement
Volumes should be relative to produced sand
Recon CHOPS Workshop Calgary Sept 21, 2011
Odyssey Tool
Recon CHOPS Workshop Calgary Sept 21, 2011
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Conventional Perf Wash Tool
Recon CHOPS Workshop Calgary Sept 21, 2011
148
Perf wash
Recon CHOPS Workshop Calgary Sept 21, 2011
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149
Perf wash
Recon CHOPS Workshop Calgary Sept 21, 2011
Just load chemical
Recon CHOPS Workshop Calgary Sept 21, 2011
75
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Chemical placed with positive perturbations
Recon CHOPS Workshop Calgary Sept 21, 2011
A Successful Odyssey Tool Job 13C-12-57-2: Production Rate of Oil/Water (m3) Versus Weeks from Before & After Usage of Pulsating Pulse Powerwave Tool 8
Pre-Powerwave Oil & Water Production Trends
7
Sparky Formation Zone
Stimulation Intervention (Approx. @ Week 6)
Production of Oil/Water (m3)
6
5
4 Post Powerwave Oil & Water Production Trends
3
2
1
0 0
5
10
15
20
25
30
# of Weeks (April 1/2010 - October 1/2010) Avg. Measured Oil (m3)
Avg. Measured Water (m3)
Linear (Avg. Measured Oil (m3))
Linear (Avg. Measured Water (m3))
Recon CHOPS Workshop Calgary Sept 21, 2011
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A successful perf wash Tool Job 9C-24-53-6: Production Rate of Oil/Water (m3) Versus Weeks from Before & After Perf Wash 25 Sparky Formation Zone Cum Oil After Intervention: 1179.01 m3 Cum Water After Intervention: 867.28 m3
Production of Oil/Water (m3)
20
Stimulation Intervention (Approx. @ Week 2)
15
10
5
0 0
1
2
3
4
5
6
7
8
9
# of Weeks (Aug 1/2010 - November30/2010) Avg.Measured Oil
Avg.Measured Water
Linear (Avg.Measured Water)
Linear (Avg.Measured Oil)
Recon CHOPS Workshop Calgary Sept 21, 2011
Odyssey Pulse Tool vs Perf Wash Tool Study
Definitions :
Technical success: Sustained production for 3 months or the limit of the data of at least half of prior peek production Pay out success: Can not be an economic success if not a technical success and has sustained production for 3 months or the limit of the data of 1.5m3/d Profitable success: Same as above but with sustained production of 5m3/d
Recon CHOPS Workshop Calgary Sept 21, 2011
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Odyssey Pulse Tool vs Perf Wash Tool Study
All wells were relatively new (i.e. weeks to 2 months)
Recon CHOPS Workshop Calgary Sept 21, 2011
Odyssey Pulse Tool vs Perf Wash Tool Study Technical Perf wash 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TTl
Fail
Payout
1 1 1
1 1 1 1 1
1 1 1
Fail Profitable
1 1 1 1 1 1 1 1 1 1 1
1 1 1 1
1
1 1 1 1
1 1
1 1
1
Fail
1
1 5
9
3
1 1 11
36%
64%
21%
79%
1
1 1 13
7%
93%
Recon CHOPS Workshop Calgary Sept 21, 2011
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Odyssey Pulse Tool vs Perf Wash Tool Study Odyssey Technical Fail 1 1 2 3 1 4 1 5 1 6 1 7 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 TTl 14
Payout
Fail
Profitable Fail 1 1 1
1
1 1 1
1
1 1
1 1 1 1 1
1 1
1 1 1 1 1 1 1 1
2
1 1 1
1 1 7
9
1 1 1 1 12
4
88% 13% 56% 44% 25% 75%
Recon CHOPS Workshop Calgary Sept 21, 2011
Odyssey Pulse Tool Different Well Set – older wells – public data Old wells Technical Fail 1 2 1 3 4 1 5 6 7 8 1 9 10 1 11 12 13 TTl 4 % 31%
Payout
Fail
1
Profitable Fail 1
1 1
1 1
1 1
1 1 1
1 1
1 1 1 1
1
1 1 1 1
1 1
1 1 1 9 69%
4 31%
1 1 1 9 69%
3 23%
1 1 1 1 1 10 77%
Recon CHOPS Workshop Calgary Sept 21, 2011
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Latest Study - ?
Started with Severe Inflow Blockage Program and Inflow and Production Impairments from Loss of Solution Gas in Cold Production - Sawatzky and Hayes Chemical pill and chase fluid volume is relative to the produced sand (i.e. 20%)
Combined intervention using Odyssey tool for chemical placement and Sebree swab tool to re-establish solution gas drive. 2 wells done to date. The first has 2 weeks of 9.3m/d production with 38.5% BS&W with 13 joint fluid level to chase. The second well operations were suspended due to extremely high sand cuts – a foam clean out is planned. 6+ jobs are in the works
Recon CHOPS Workshop Calgary Sept 21, 2011
Loss of Solution Gas
Reservoir heterogeneity Asymmetric drainage geometry from wormhole growth Blockages caused by formation debris Water and/or gas breakthrough Casing venting during production interruption or production suspension Under balance events during drilling and/or completions
While producing the more mobile portions of the reservoir, the less mobile become more so
Recon CHOPS Workshop Calgary Sept 21, 2011
80
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Sebree Swab Stimulation on a Disposal Well
In 9hrs recovered 158m3 of water and 25m3 of sand Prior injection was less than 300m3/d and inadequate Currently the well is taking 400m/d on vacuum
Recon CHOPS Workshop Calgary Sept 21, 2011
Sebree Swab Tool Current Initiative
Rigless Completions:
Manage completion and construction costs on new drills To ensure inflow is established from problems such as low pressure, drilling damage and reluctant gas break out. To enhance gas break out and conform sand failure; optimizing drainage geometry
Recon CHOPS Workshop Calgary Sept 21, 2011
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200
150
100
50
Pattern 1 Oil Rate
Pattern 2 Oil Rate
Pattern 3 Oil Rate
2.6 %/mo Harm. Decl.
Decline Match Points
Pattern 1 Powerwave
Pattern 2 Powerwave
Pattern 3 Powerwave
01/11/08
01/10/08
01/09/08
01/08/08
01/07/08
01/06/08
01/05/08
01/04/08
01/03/08
01/02/08
01/01/08
01/12/07
01/11/07
01/10/07
01/09/07
01/08/07
01/07/07
01/06/07
01/05/07
01/04/07
01/03/07
01/02/07
01/01/07
01/12/06
0 01/11/06
Oil Rate (bopd) - 3 Powerwave Patterns
250
Case History – Alberta Pressure Pulsed Water Flooding
Recon CHOPS Workshop Calgary Sept 21, 2011
Pulsed Polymer Flooding
Conventional water flooding is expanding to more viscous reservoirs Pressure pulsed water flooding currently deployed in 500 – 1000cps reservoirs CNRL‟s polymer flooding experience is economically successful up to 10,0000cps or greater Pulsed polymer flooding will be able to increase flooding applications to - ? Its possible to implement pulsed polymer flooding very soon Pulsed polymer flooding is the least riskiest EOR option Imagine pressure supported production in the CHOPS region Recon CHOPS Workshop Calgary Sept 21, 2011
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Enormous Drainage Geometries
after Andrew Squires and Earl Jensen
Recon CHOPS Workshop Calgary Sept 21, 2011
.
Recon CHOPS Workshop Calgary Sept 21, 2011
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Recon CHOPS Workshop Calgary Sept 21, 2011
Dual induction and SFL curve example
84
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Recon CHOPS Workshop Calgary Sept 21, 2011
Potential Water Sources in Oil and Gas Wells
“Extraneous” Water Seal
Gas Cap
Oil
Wormhole Formation Water
Seal
“Extraneous” Water
Recon CHOPS Workshop Calgary Sept 21, 2011
85
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Production Water Origin and Isotopic Changes with Time/ Source 0
100%
Progressive incursion of water from non-producing zone (formation "B") results in intermediate compositions.
-20
Mass-Balance equations may determine how much of each water source is being produced.
-40 Formation "B" Water cut may or may not increase.
-60 % Water Cut
-80
Water Incursion (Behind Pipe)
Initial Production Water Composition (Sw)
-100 Formation "A" Water Coning Trend
0%
-120 0
2
4
6
8
10
12
14
16
Time Recon CHOPS Workshop Calgary Sept 21, 2011
Recon CHOPS Workshop Calgary Sept 21, 2011
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HDD Examples 133 Samples Per Meter (SPM)
Demonstrates value for picking intervals to avoid shale damage Demonstrates the potential for exploiting oil over water where vertical permeability impairments exist – current works in progress Ex 4
Recon CHOPS Workshop Calgary Sept 21, 2011
Ex. 1 Mini Plot
Perfs 535 -538 Of interest 547 -550 vertical permeability impairment may stop bottom water?
87
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Ex. 1
Perforated interval
Ex. 1
Permeability impairment
88
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Ex. 3 Mini Plot
Perfs 525 – 527.5 Of interest 534 -535 vertical permeability impairment may stop bottom water?
Ex. 3
Perforated interval
89
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EX 4
EX 4
Proposed perfs
Permeability impairments
Recon CHOPS Workshop Calgary Sept 21, 2011
90
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HDD Example 5
Demonstrates value for picking gas interval permeability 442.3 – 442.5 over possible water ??? Demonstrates thin zone between carbonate lenses at 447.2 – 447.7
Recon CHOPS Workshop Calgary Sept 21, 2011
Ex 5
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Ex 5
Proposed perfs
Proposed perfs
Recon CHOPS Workshop Calgary Sept 21, 2011
High Resolution Example
Schlumberger high definition log Demonstrates laminate cap rock Example well had severe inflow blockage (see pictures from intervention) Perforations 446.0 to 452.0
Recon CHOPS Workshop Calgary Sept 21, 2011
92
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Normal Resolution
Recon CHOPS Workshop Calgary Sept 21, 2011
High Resolution
Recon CHOPS Workshop Calgary Sept 21, 2011
93
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Recon CHOPS Workshop Calgary Sept 21, 2011
A Completion Example Proposed 8 meters of perforations
Recon CHOPS Workshop Calgary Sept 21, 2011
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A Completion Example High Definition Data (HDD) Log Suggested 3.4 meters of perforations Only shot 1.8 meters too much sand inflow rigless operation Well produced about 15m3/d
Recon CHOPS Workshop Calgary Sept 21, 2011
Top Water Example of Extreme Density Oil
Recon CHOPS Workshop Calgary Sept 21, 2011
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Questions and Discussions
Recon CHOPS Workshop Calgary Sept 21, 2011
96