This paper describes the selection, design, successful application and performance monitoring of Electrical Submersible pumps in the giant Mangala oil field and Thumbli water field situated in the Barmer basin in Rajasthan, India. Mangala oil field contains approximately 1.3 billion barrels of STOIIP in high-quality fluvial reservoirs. The field was brought on production in August 2009 and is currently producing at the plateau production rate of 150,000 bopd of which approximately 40% of the oil production is from the ESP oil wells.
To support the water requirement of Mangala and other satellite oil fields, Thumbli source water field was developed with 5 water production wells with up to 4 wells operating at a time. Each of these water wells is installed with 60,000 bwpd capacity pumps and the field is currently producing up to 225,000 bwpd to meet the water requirements of Mangala and other satellite fields.
The Mangala oil field is a multilayer, multi-Darcy reservoir, has waxy viscous crude with in-situ oil viscosity up to 22 cp and wax content in the range of 18 to 26%. The field was developed using hot water flood for pressure maintenance. Significant production challenges included unfavorable mobility ratio with early water cut and hence the early requirement of artificial lift to maintain the plateau production rate. The field has 12 horizontal producers and 100 deviated producers. ESP was selected as the artificial lift mode for the high rate horizontal producers while hot water jet pumping was selected as the artificial lift mode for low rate deviated oil wells. Each horizontal well is capable of producing up to 15,000 blpd and high rate ESPs were designed and installed to deliver the production requirement. Currently 8 of the 11 horizontal producers are on ESP lift and the remaining three wells are planned for ESP installation in the near future. Apart from two early ESP failures during installation, ESPs have had a good run life; the paper also describes lessons learnt from the infant mortalities.
The Thumbli water field, located ~20 km southeast of Mangala field has been developed to meet the water requirement of Mangala and other satellite fields. Thumbli water aquifer is a shallow water field which contains water of ~ 5000 ppm salinity with dissolved CO2, oxygen, chlorides and SRB. 5 high capacity water wells were drilled in Thumbli field to meet the huge water demand from Mangala for water injection in Mangala and satellite field injector wells, hot water circulation in oil production wells and associated water requirement for boilers etc. 1000 HP water well ESPs were designed to produce up to 60,000 bwpd from each well with installed water production capacity of up to 300,000 bwpd from Thumbli field.
Over the last several years, horizontal drilling and multi-stage hydraulic fracturing have become the norm across the industry and proved crucial for economic production of natural gas from unconventional shale gas and ultra tight sandstone reservoirs, also referred to as nano-Darcy reservoirs.
Following the success of the Barnett shale, horizontal drilling and multi-stage hydraulic fracturing has spread across North America with new emerging shale gas plays such as the Eagle Ford, Woodford, Haynesville, Marcellus, Utica, Horn River
changing the industry's landscaping. In the current economic environment of high drilling and completion costs, coupled with lower commodity prices, the economic success of shale gas developments has become reservoir specific.
Evaluation of well's initial performance in a particular field and especially the ability to accurately predict the long term production behavior and EUR is critical to the efficient deployment of large capital investments. Field analogies making use
of arbitrary "type curves?? can have a significant negative impact on the project's bottom line.
With the growing number of multi-stage horizontal wells producing from shale gas reservoirs, many "unconventional?? production analysis techniques have been developed based on new concepts such as stimulated reservoir volume (SRV),
fracture contact area (FCA), or sophisticated mathematical relationships (power law decline curves, linear flow type curves, to name a few). These sophisticated engineering processes are well documented in the literature and have been presented at
numerous industry work shops and conferences. However, for the majority of these techniques there is one common reoccurring theme: performance evaluation of shale gas production cannot be analyzed using conventional methods (e.g.
This paper will demonstrate how the conventional approach of reservoir characterization, well performance evaluation and forecasting, can be implemented for all unconventional gas reservoirs, using traditional well testing and production data
analysis techniques. We will present one simple analytical model based on the solution of the pseudo steady state equation and will introduce the concept of a shale gas normalized production plot. In our view, the shale gas normalized production
plot is one type curve generally applicable to any shale gas reservoir.
Finally, pre-frac in-situ testing techniques will be reviewed and special consideration will be given to the perforation inflow diagnostic (PID) testing. We will emphasize the importance of specific reservoir parameters (pore pressure and in-situ shale
matrix permeability) and show their impact on drilling and completion strategy and design. Field case examples including well test results and production data from wells completed in several shale gas reservoirs are presented.
This paper presents a methodology for connecting geology, hydraulic fracturing, economics, environment and the global natural gas endowment in conventional, tight, shale and coalbed methane (CBM) reservoirs. The volumetric estimates are generated by a variable shape distribution model (VSD). The VSD has been shown in the past to be useful for the evaluation of conventional and tight gas reservoirs. However, this is the first paper in which the method is used to also include shale gas and CBM formations.. Results indicate a total gas endowment of 70000 tcf, split between 15000 tcf in conventional reservoirs, 15000 tcf in tight gas, 30000 tcf in shale gas and 10000 tcf in CBM reservoirs. Thus, natural gas formations have potential to provide a significant contribution to global energy demand estimated at approximately 790 quads by 2035.
A common thread between unconventional formations is that nearly all of them must be hydraulically fractured to attain commercial production. A significant volume of data indicates that the probabilities of hydraulic fracturing (fracking) fluids and/or methane contaminating ground water through the hydraulically-created fractures are very low. Since fracking has also raised questions about the economic viability of producing unconventional gas in some parts of the world, supply cost curves are estimated in this paper for the global gas portfolio. The curves show that, in some cases, the costs of producing gas from unconventional reservoirs are comparable to those of conventional gas.
The conclusion is that there is enough natural gas to supply the energy market for nearly 400 years at current rates of consumption and 110 years with a growth rate in production of 2% per year. With appropriate regulation, this may be done safely, commercially, and in a manner that is more benign to the environment as compared with other fossil fuels.
The high decline rate observed in over pressured shale has attracted the attention of the industry, and better well management procedures for long term productivity improvement are still evolving. Operators are recognizing some benefit in controlled rate (controlled drawdown) production as one way of improving well performance for the wells in over pressured stress sensitive formations.
During uncontrolled rate production because of high drawdown, the permeability in stress sensitive shales decays faster because of increased stress. Often high initial gas rate is accompanied by high decline rate as the permeability reduction takes effect. In addition, proppant could also be produced back, crushed or embedded in the formation. However, controlled rate production minimizes the rate decline, albeit at reduced initial gas rate. Modelers resort to using different stress permeability decay coefficients for these two production strategies. Higher values are assigned to uncontrolled rate production to produce lower EUR. This approach, although convenient, requires different permeability versus stress tables depending on the production strategy.
Porosity and pore volume reduction in shales could be as high as 20 percent due to changes in net stress. The pore volume reduction provides in situ energy for gas recovery. The increased rate of permeability decay due to changing in situ stresses reduces the effectiveness of pressure support from pore volume reduction as fractures close under stress.. Controlled rate production strategy slows down permeability decay rate and this enables better use of pore volume energy. The pore volume consideration could provide additional gain to EUR for controlled rate.
Our analytical simulation model couples geomechanics permeability and porosity stress coefficients and evaluates well performance under moderate and low net stress sensitivity. Haynesville and Marcellus shales were evaluated. The importance of pore volume stress effect from the stand point of well performance evaluation and reservoir characterization is assessed.
The Stybarrow Field is a moderately sized biodegraded 22° API oil accumulation reservoired in Early Cretaceous sandstones of the Macedon Formation in the Exmouth Sub-Basin, offshore Western Australia. The reservoir is comprised of excellent quality, poorly consolidated turbidite sandstones up to 20m thick. The field lies in approximately 800m of water and has been developed with five near-horizontal producers and three water injection wells. The Stybarrow development came online at an initial rate of 80,000BOPD in November 2007.
Due to the lack of significant aquifer support, water injection was planned from start-up for pressure maintenance. Acquisition of a variety of data types have enabled key subsurface challenges to be addressed both before and during production. Structural and stratigraphic complexities influence connectivity and therefore must be fully evaluated in order to achieve optimal sweep. A feasibility study concluded that Stybarrow would be a good candidate for 4D seismic monitoring. Two monitor surveys were acquired and, along with other reservoir surveillance techniques, have been used to refine the geological model.
The first monitor survey at Stybarrow was recorded in November 2008. The results of this survey were in agreement with prior 4D modelling and supported the drilling of a successful development well in the north of the field. A second monitor survey was recorded in May 2011, three and a half years after first oil and at 70% of expected ultimate recovery. This survey is currently being analysed to determine if sweep patterns have changed.
The 4D surveys have proven to be an important tool for understanding subsurface architecture and dynamic fluid-flow behaviour. The results of both 4D seismic surveys have provided significant contributions to understanding the dynamic behaviour within the reservoir to facilitate optimal reservoir management.
The Pyrenees Development comprises three oil and gas fields: Ravensworth, Crosby and Stickle. The fields are located in production licenses WA-42-L and WA-43-L, offshore Western Australia, in the Exmouth Sub-basin and are operated by BHP Billiton (Fig. 1). Eighteen subsea wells, including 14 horizontal producers, 3 vertical water disposal wells and 1 gas injection well have been constructed to date and additional wells are planned for infill and to develop additional resources. First oil was achieved during February 2010 and production exceeded 50 million barrels in November 2011.
The Pyrenees fields are low relief, with oil columns of approximately 40 metres within excellent quality reservoirs of the Barrow Group. The 19° API crude has moderate viscosity, low gas / oil ratio (GOR), and a strong emulsion forming tendency which makes oil/water separation and accurate well test metering difficult. Early in the project design phase it was identified that the complex subsea gathering system and the need to reduce measurement uncertainties would dictate special attention to production measurement.
Subsea multiphase flow meters (MPFMs) were specified to meet the challenges of production optimization and allocation while at the same time minimizing production deferral for separator testing. Each oil producer is monitored by a dedicated MPFM. With 14 meters, Pyrenees is among the largest subsea MPFM installations worldwide.
This paper describes the process of MPFM qualification and commissioning together with their performance over 2 years in the field. We show how close cooperation between the Operator and MPFM Vendor has enabled quality rate measurements of emulsified production despite large changes in producing gas/oil ratio and water cut.
While the primary justification for Pyrenees subsea MPFMs was production allocation and optimization, interpretation of transient water cut and GOR data proved valuable for production and reservoir engineering applications. Examples of proactive reservoir and production management including optimizing drawdown of Inflow Control Device (ICD) equipped wells, optimizing well lineup and gas lift to commingled wells are presented.
Producing and delivering North West Australia (NWA) deepwater gas reserves to LNG plants poses unique challenges. These include extreme metocean conditions, unique geotechnical conditions, long distances to infrastructure and high reliability/availability requirement of supply for LNG plants. A wet or dry tree local floating host platform will be required in most cases. Whereas semisubmersible, TLP, Spar and floating LNG (FLNG) platform designs all have the attributes to be a host facility, none has been installed in this region to date.
This paper will address important technical, commercial and regulatory factors that drive the selection of a suitable floating host platform to develop these deepwater gas fields off NWA. Linkages between key reservoir and fluid characteristics and surface facility requirements will be established. A focus will be on the unique influence of regional drivers and site characteristics including metocean and geotechnical conditions, water depths and remoteness of these fields.
There have been 17 FPSOs producing oil in Australian waters. These facilities have been chosen because of the remoteness of the fields and the lack of pipeline and process infrastructure. Storing oil on the FPSO for offloading and shipping from the fields becomes an obvious solution. Semisubmersible, TLP or Spar platforms show little advantage in such developments.
For deepwater gas developments, the product has to be processed, compressed and piped to shore for liquefaction. As host processing facilities, Semisubmersible, TLP and Spar platforms have clear advantages over FPSOs because of their superior motion performance in the harsh Australian metocean environment and other benefits such as facilitating drilling, dry tree completion and well services. FPSOs or FSOs may be applied for storage of associated oil and condensates. For marginal and remote gas field developments, an LNG FPSO (FLNG) may be an attractive option as it eliminates long pipelines and land-based liquefaction plants.
As discussed by Dorgant and Stingl (2005), a deepwater field development life cycle following discovery usually involves five distinct phases, Figure 1. The "select?? phase occurs after a discovery has been appraised sufficiently to further evaluate it for development. It consists of evaluating multiple development concepts and scenarios and selecting the one that will most likely achieve the identified commercial and strategic goals. Selecting a floating platform and its functions for a deepwater development is an important subset of the select phase and the overall field development planning.
The process of field development planning involves a complex iterative interaction of its key elements (subsurface, drilling and completions, surface facilities) subject to regional and site constraints (D'Souza, 2009). The objective is to select a development plan that satisfies an operator's commercial, risk and strategic requirements. It entails developing a robust and integrated reservoir depletion plan with compatible facility options. The selection occurs while uncertainty in critical variables that determine commercial success (well performance, reserves) is high. One of the challenges is to select a development plan that manages downside reservoir risk (considering the very large capital expense involved) while having the flexibility to capture its upside potential.
Low matrix permeability and significant damage mechanisms are the main signatures of tight gas reservoirs. During drilling and fracturing of tight formations, the wellbore liquid invades the tight formation, increases liquid saturation around wellbore and eventually reduces permeability at near wellbore. The liquid invasion damage is mainly controlled by capillary pressure and relative permeability curves.
Water blocking and phase trapping damage is one of the main concerns in use of water based drilling fluid in tight gas reservoirs, since due to high critical water saturation, relative permeability effects and strong capillary pressure, tight formations are sensitive to water invasion damage. Therefore, use of oil based mud may be preferred in drilling or fracturing of tight formation. However invasion of oil filtrate into tight formations may result in introduction of an immiscible liquid hydrocarbon drilling or completion fluid around wellbore, causing entrapment of an additional third phase in the porous media that would exacerbate formation damage effects.
This study focuses on phase trapping damage caused by liquid invasion using water-based drilling fluid in comparison with use of oil-based drilling fluid in water sensitive tight gas sand reservoirs. Reservoir simulation approach is used to study the effect of relative permeability curves on phase trap damage, and results of laboratory experiments core flooding tests in a West Australian tight gas reservoir are shown in which the effect of water injection and oil injection on the damage of core permeability are studied. The results highlights benefits of using oil-based fluids in drilling and fracturing of tight gas reservoirs in term of reducing skin factor and improving well productivity.
Tight gas reservoirs normally have production problems due to very low matrix permeability and different damage mechanisms during well drilling, completion, stimulation and production (Dusseault, 1993). The low permeability gas reservoirs can be subject to different damage mechanisms such as mechanical damage to formation rock, plugging of natural fractures by invasion of mud solid particles, permeability reduction around wellbore as a result of filtrate invasion, clay swelling, liquid phase trapping, etc (Holditch, 1979).
In general, for tight sand gas reservoirs, average pore throat radius might be very small and therefore it may create tremendous amounts of capillary forces. Capillary forces cause the spontaneous imbibition of a wetting liquid (in this case water) in the porous medium in the absence of external forces such as a hydraulic gradient (Bennion and Brent, 2005). This causes significantly high critical water saturation (Bennion et al., 2006). Two forces drive capillary flow (Adamson and Gast, 1997). The first is the reduction in the surface free energy by the wetting of the hydrophilic surface (wettability). In hydraulic fracturing, water in the fracturing fluid wets the surface of the pores in the rock, resulting in a decrease in the surface free energy of the pores. The other force that drives capillary flow is the capillary pressure.
Tight gas reservoirs might be different in term of initial water saturation (Swi) compared with critical water saturation (Swc), depending on the geological time of gas migration to the reservoir. Initial water saturation might be normal, or in some cases sub-normal (Swi less than Swc) due to water phase vaporization into the gas phase (Bennion and Thomas, 1996). The initial water saturation might also be more than Swc if the hydrocarbon trap is created during or after the gas migration time. A sub-normal initial water saturation in tight gas reservoirs can provide higher relative permeability for the gas phase (effective permeability close to absolute permeability), and therefore relatively higher well productivity (Bennion and Brent, 2005).
The first hydraulically operated completion was installed in Australia in 2004 (Guatelli et al 2004). Since then, a number of intelligent completions have been installed in offshore Australia. The remoteness of offshore Australia, particularly in the Timor Sea area, means intervention vessels are not readily available and well interventions are costly operations. For this reason, intelligent completion is considered to be an attractive alternative, by providing a down-hole solution to actively manage the reservoir production life and delay potential water breakthrough.
The Kitan oil field is remotely located in the Joint Petroleum Development Area (JPDA) between East Timor and Australia. The Kitan oil field production facilities consist of three vertical producing wells, subsea flowlines, risers, and one Floating Production Storage and Offloading (FPSO) facility. The wells were completed with an intelligent design and cleaned up using a rig before the FPSO arrived on location.
The intelligent completion design consists of two multi-stage hydraulic down-hole Flow Control Valves (FCVs) and three Down-Hole Gauges (DHGs) to independently control and monitor two different production zones. The FCVs have a total of 8 positions (fully opened, fully closed and 6 intermediate choke positions).
It is planned to close the lower FCV to shut off water production from the lower zone while the upper FCV remains fully opened over the field life. The different FCV choke positions were utilized during the field startup and during the early stages of production while the water cut was still low, to overcome unforeseen technical limitations in the production system, and to optimize hydrocarbon production.
This paper describes various aspects of the Kitan oil field intelligent well completion from design through installation and field startup to early stage of production operations, and includes technical problems encountered during the field startup as well as lessons learnt.
Healy, John C. (John C. Healy Jr Consulting LLC) | Sanford, John R. (ENI International Resources Ltd) | Reeves, Donald Franklin (Noble Energy Inc.) | Dufrene, Kerby John (Schlumberger) | Luyster, Mark R. (M-I Swaco) | Offenbacher, Matthew A. (MI-SWACO) | Ezeigbo, Chinyereze (M-I Swaco)
A case history from Offshore Israel is presented that describes the successful delivery of two ultra high-rate gas wells (>200 MMscf/D) completed in a depleted gas reservoir with 9??-in. production tubing and an openhole gravel pack (OHGP). Maximizing gas off-take rates from a volumetric drive gas reservoir that possesses high flow capacity (kh) requires large internal diameter (ID) tubing coupled with efficient sand face completions. When sand control is required, the OHGP offers the most efficient as well as the most reliable, long-term track record of performance. A global study of wells completed with 9??-in. production tubing ("big bore??) determined that this design concept was feasible and deliverable in a short time frame while still maintaining engineering rigor. The paper will highlight key accomplishments within various phases of a completion delivery process with particular emphasis on the sand control design, testing and execution. The completions were installed with minimal issues (NPT ˜ 9%) and have produced without incident. The two wells, Mari-B #9 and #10, achieved a peak gas rate of 223 and 246 MMscf/D, respectively.