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Haghighi, M (The University of Adelaide) | O'Reilly, DI (Chevron Australia Pty Ltd, The University of Adelaide) | Hunt, AJ (Chevron Australia Pty Ltd) | Sze, ES (Chevron Australia Pty Ltd) | Hopcroft, BS (Chevron Australia Pty Ltd) | Goff, BH (Chevron Australia Pty Ltd)
This paper demonstrates how good technical evaluations and focused operational application can enhance the value of a mature asset. The Windalia reservoir underlies Barrow Island (BWI), situated 56 km from the coast of Western Australia, and has produced oil since 1965. Waterflooding commenced shortly after initial production, in 1967, and remains the main drive mechanism in the field today. Throughout the life of this onshore field, water injection and oil production have varied according to asset strategy and economic conditions. In this case study, we share how recent improvements made in the areas of Reservoir Surveillance and Operations activities have increased water injection efficiency and total oil recovery.
Through the use of new methods and workflows, the BWI Sub-Surface team was able to target specific areas of the field to distribute water to in order to increase injection and maximise oil production. For example, new workflows were built with the real-time PI monitoring system to analyse Pressure Fall Off (PFO) tests from each of the 147 waterflood patterns in detail. Capacitance-Resistance-Modeling was also leveraged to guide individual well target injection-rates. Operationally, several projects were also initiated to increase water injection into the right areas of the field.
The new Reservoir Management approach has significantly increased the volume of water being injected into the areas of need, supporting improved levels of oil production. For the first time in almost 10 years, the stream-day water injection rate has exceeded 90,000 bwipd. The results from PFO transient interpretation and pattern balancing proved effective in directing water to low-pressure, high-GOR areas of the field. They also provided valuable information about formation perm-thickness and skin. The phenomenon of water-cycling was also largely avoided, owing to close monitoring of production well tests and water injector transient surveys.
The present work addresses reservoir and operational aspects of Australia's largest active waterflood. The lessons shared are highly applicable to a low oil price environment, as they show how fit-for-purpose and low-cost acquisition of reservoir data can lead to improved field performance.
DI, O'Reilly (Chevron Australia Pty Ltd, The University of Adelaide) | BS, Hopcroft (Chevron Australia Pty Ltd) | KA, Nelligan (Chevron Australia Pty Ltd) | GK, Ng (Chevron Australia Pty Ltd) | BH, Goff (Chevron Australia Pty Ltd) | M, Haghighi (The University of Adelaide)
Barrow Island (BWI), 56 km from the coast of Western Australia, is home to several mature reservoirs that have produced oil since 1965. The main reservoir is the Windalia sandstone, and it has been waterflooded since 1967, while all the other reservoirs are under primary depletion. Due to the maturity of the asset, it is economically critical to continue to maximise oil production rates from the 430 online, artificially lifted wells. It is not an easy task to rank well stimulation opportunities and streamline their execution. To this end, the BWI Subsurface Team applied Lean Six Sigma processes to identify opportunities, increase efficiency and reduce waste relating to well stimulation and well performance improvement.
The Lean Sigma methodology is a combination of "Lean Production" and "Six Sigma" these are methods used to minimise waste and reduce variability respectively. The methods are used globally in many industries, especially those involved in manufacturing. In this asset, we applied the processes specifically to well performance improvement through stimulation and other means. The team broadly focused on categorising opportunities in both production and injection wells and ranking them, specifically: descaling wells, matrix acidising, sucker rod optimisation, reperforating and proactive workovers. The process for performing each type of job was mapped and bottlenecks in each process isolated.
Upon entering "Control" phase, several opportunities had been identified and put in place. Substantial improvements were made to the procurement, logistics and storage of hydrochloric acid (HCl) and associated additives, enabling quicker execution of stimulation work. A new programme was also developed to stimulate wells that had recently failed and were already awaiting workover, which reduced costs. A database containing the stimulation opportunities available at each individual well assisted with this process. The project resulted in the stimulation of several wells in the asset with sizable oil rate increases in each.
This case study will extend the information available within the oil-industry literature regarding the application of Lean Sigma to producing assets. It will assist other Operators when evaluating well stimulation opportunities in their fields. Technical information will be shared regarding feasibility studies (laboratory compatibility work and well transient testing results) for acid stimulation and steps that can be taken to streamline the execution of such work. Some insights will also be shared regarding the most efficient manner to plan rig-work regarding stimulation workovers.